Cost effective cartridge for a plasma arc torch

ABSTRACT

An adapter for a plasma arc torch comprising a torch body is provided. The adapter includes a body defining a longitudinal axis between a proximal end and a distal end and at least one protruding portion extending from the proximal end of the body. The at least one protruding portion is configured to be inserted into a cavity of the torch body to physically engage a switch inside of the cavity. The engagement of the switch is adapted to indicate installation of a consumable component in the plasma arc torch.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. Ser. No. 17/036,921, filed Sep.29, 2020, which is a continuation-in-part of U.S. Ser. No. 16/677,175,issued as U.S. Pat. No. 11,432,393 on Aug. 30, 2022, which is acontinuation-in-part of U.S. Ser. No. 16/413,071, filed May 15, 2019,which is a divisional application of Ser. No. 15/043,028, issued as U.S.Pat. No. 10,321,551 on Jun. 11, 2019, which is a continuation-in-part ofU.S. Ser. No. 14/824,946, issued as U.S. Pat. No. 10,582,605 on Mar. 3,2020, which claims the benefit of and priority to U.S. ProvisionalPatent Application No. 62/036,393, filed Aug. 12, 2014. Application Ser.No. 16/677,175 also claims the benefit of and priority to U.S.Provisional Patent Application No. 62/756,996, filed Nov. 7, 2018.Application Ser. No. 16/677,175 is also a continuation-in-part of U.S.Ser. No. 15/971,703, issued as U.S. Pat. No. 10,960,485 on Mar. 20,2021, which is a continuation of U.S. Ser. No. 14/708,957, issued asU.S. Pat. No. 9,981,335 on May 29, 2018, which is a continuation-in-partof U.S. Ser. No. 14/079,163, filed Nov. 13, 2013. Application Ser. No.14/708,957 claims the benefit of and priority to U.S. Ser. No.61/991,114, filed May 9, 2014 and U.S. Ser. No. 62/036,393, filed Aug.12, 2014. Application Ser. No. 14/708,957 is also a continuation-in-partof International Patent Application No. PCT/US14/56546, filed Sep. 19,2014. Application Ser. No. 15/971,703 is also a continuation-in-part ofU.S. Ser. No. 14/708,972, issued as U.S. Pat. No. 10,456,855 on Oct. 29,2019 and a continuation-in-part of U.S. Ser. No. 14/824,946, issued asU.S. Pat. No. 10,582,605 on Mar. 3, 2020. The entire contents of theseapplications are owned by the assignee of the instant application andincorporated herein by reference in their entireties.

TECHNICAL FIELD

The present invention generally relates to cartridges for a contactstart plasma arc torch, and more particularly, to one or morereplaceable, low-cost cartridges, each having multiple integratedcomponents.

BACKGROUND

Thermal processing torches, such as plasma arc torches, are widely usedfor high temperature processing (e.g., heating, cutting, gouging andmarking) of materials. A plasma arc torch generally includes a torchbody, an electrode mounted within the torch body, an emissive insertdisposed within a bore of the electrode, a nozzle with a central exitorifice mounted within the torch body, a shield, electrical connections,passages for cooling, passages for arc control fluids (e.g., plasma gas)and a power supply. A swirl ring can be used to control fluid flowpatterns in the plasma chamber formed between the electrode and thenozzle. In some torches, a retaining cap is used to maintain the nozzleand/or swirl ring in the plasma arc torch. In operation, the torchproduces a plasma arc, which is a constricted jet of an ionized gas withhigh temperature and sufficient momentum to assist with removal ofmolten metal. Gases used in the torch can be non-reactive (e.g., argonor nitrogen), or reactive (e.g., oxygen or air).

One method for producing a plasma arc in a plasma arc torch is thecontact start method. The contact start method involves establishingphysical contact and electrical communication between the electrode andthe nozzle to create a current path between them. The electrode and thenozzle can cooperate to create a plasma chamber within the torch body.An electrical current is provided to the electrode and the nozzle, and agas is introduced to the plasma chamber. Gas pressure builds up untilthe pressure is sufficient to separate the electrode and the nozzle. Theseparation causes an arc to be formed between the electrode and thenozzle in the plasma chamber. The arc ionizes the introduced gas toproduce a plasma jet that can be transferred to the workpiece formaterial processing. In some applications, the power supply is adaptedto provide a first electrical current known as a pilot current duringgeneration of the arc and a second current known as a transferred arccurrent when the plasma jet has been transferred to the workpiece.

Various configurations are possible for generating the arc. For example,the electrode can move within the torch body away from the stationarynozzle. Such a configuration is referred to as the “blow-back” contactstart method because the gas pressure causes the electrode to move awayfrom the workpiece. A problem with such systems relates to precisealignment of the nozzle and electrode consumables, which significantlyimpacts life expectancy of the consumables and material processing/cutquality. In another configuration, the nozzle can move away from therelatively stationary electrode. Such a configuration is referred to asthe “blow-forward” contact start method because the gas pressure causesthe nozzle to move toward the workpiece.

Existing plasma cutting systems include a large array of separateconsumables available for use with different currents and/or operatingmodes. The large number of consumable options requires large part countsand inventories for users, and can confuse users and increase thepossibility of installing incorrect consumables. The large number ofconsumable options can also cause lengthy torch setup time(s) and makeit difficult to transition among cutting processes that requiredifferent arrangements of consumables in the torch, arrangement andinstallation of which is often performed in the field one component at atime. For example, before a cutting operation, selecting and installingthe correct set of consumables for a particular cutting task can beburdensome and time-consuming. Furthermore, selection, assembly, andinstallation of these components in the field can cause alignment issuesor compatibility issues when old components are used with newcomponents. During torch operation, existing consumables can experienceperformance issues such as failing to maintain proper consumablealignment and spacing. Furthermore, current consumables includesubstantial amounts of expensive materials (e.g., Vespel™) and oftenrequire a relatively complex manufacturing process, which leads tosignificant manufacturing costs and inhibits their widespreadcommercialization, production and adoption. What is needed is a new andimproved consumable platform that decreases manufacturing costs andtime, decreases part count, increases system performance (e.g.,component alignment, cut quality, consumable life,variability/versatility, etc.), and eases installation and use ofconsumables by end users.

SUMMARY

The present invention provides one or more integrated, cost-effectivecartridge designs for a plasma arc torch, such as for amanually-operated, air-cooled plasma arc torch. Generally, because acartridge includes a suite of two or more consumable components, itprovides ease of use and shortens the time for installation into aplasma arc torch in comparison to installing each consumable componentindividually. In addition, the use of a cartridge in a torch improvescomponent alignment and cut consistency. However, manufacturing andmaterial costs can prohibit the widespread commercialization andproduction of cartridges. The present invention solves this problem byproviding one or more cost effective cartridge designs that facilitatecartridge commercialization and production and improve theirinstallation.

The invention, in one aspect, features a cartridge for an air-cooledplasma arc torch. The cartridge comprises a swirl ring and a crown. Theswirl ring includes a molded thermoplastic elongated body having asubstantially hollow portion, the molded thermoplastic elongated bodyhaving a distal end and a proximal end and configured to receive anelectrode within the hollow portion. The swirl ring also includes aplurality of gas flow openings defined by the distal end of theelongated body and configured to impart a swirling motion to a plasmagas flow for the plasma arc torch. The swirl ring further includes anozzle retention feature on a surface of the elongated body at thedistal end for retaining a nozzle to the elongated body. The crown isaffixed to the proximal end of the elongated body of the swirl ring. Thecrown substantially encloses the proximal end of the elongated body.

In some embodiments, the crown is formed of an electrically conductivematerial. The crown can be configured to retain the electrode within thecartridge and pass an electrical current to the electrode. The crown cancomprise a biasing surface for physically contacting a resilient elementthat biases against a proximal end of the electrode. Additionally, thecrown can comprise a substantially hollow body configured to retain theresilient element between the biasing surface and the proximal end ofthe electrode.

In some embodiments, the body of the crown has a substantially uniformthickness. In some embodiments, the crown includes at least one venthole.

In some embodiments, the crown comprises a contact surface forfacilitating electrical contact with a corresponding contact surface ofthe electrode when the plasma arc torch is operated in a transferred arcmode. The contact surface of the crown is characterized by the absenceof contact with the corresponding contact surface of the electrodeduring initiation of a pilot arc. The contact surface can be configuredto physically contact the corresponding contact surface of the electrodewhen the torch is operated in the transferred arc mode.

In some embodiments, the plurality of gas flow openings of the swirlring include slots defined by a plurality of extensions disposed aboutthe distal end of the elongated body of the swirl ring, each slotsituated between a pair of the extensions.

In some embodiments, the nozzle retention feature includes a groovelocated on an external surface of the extensions. Retention of thenozzle to the swirl ring can be via one of snap fit, threading orcrimping. In some embodiments, engagement between the crown and theswirl ring is by one of crimping, snap fit, or threading.

In some embodiments, the elongated body of the swirl ring is molded froma thermoplastic material comprising a polymer formed of ether and ketonemolecules. The thermoplastic material can have one or more propertiescomprising (i) a glass transition temperature (Tg) of greater than about320 Fahrenheit (F), (ii) a coefficient of linear thermal expansion(CLTE) of less than about 22 micro-inch/inch-Fahrenheit (micro·in/in·F)below Tg, (iii) a CLTE of less than about 55 micro·in/in·F above Tg,(iv) a melting point of greater than about 720 Fahrenheit, and (v) adielectric strength of greater than about 480 kilo-volt/inch.

In some embodiments, the ratio of an axial length (L) of each gas flowopening to an average radius (R) between the radius of the electrode andthe radius of an inner wall of the swirl ring is less than about 0.5. Insome embodiments, the plurality of gas flow openings are disposed in asingle layer about the distal end of the elongated body, each gas flowopening having an offset of about 0.040 inches between an opening in aninner wall of the swirl ring and an opening on an outer wall of theswirl ring.

In another aspect, a molded swirl ring for an air-cooled plasma arctorch is provided. The molded swirl ring comprises a moldedthermoplastic elongated body comprising a substantially hollow portion.The molded thermoplastic elongated body has a distal end and a proximalend and configured to receive an electrode within the hollow portion.The molded swirl ring also includes a plurality of molded gas flowopenings each extending from an interior surface to an exterior surfaceof the elongated body. The molded gas flow openings are disposed aboutthe distal end of the elongated body and configured to impart a swirl toa plasma gas flow of the plasma arc torch. The molded swirl ring furtherincludes a nozzle retention surface on the body for retaining a nozzleat the distal end of the elongated body.

In some embodiments, the plurality of gas flow openings include slotsdefined by a plurality of extensions disposed about the distal end ofthe elongated body, each slot situated between a pair of the extensions.The distal end of the elongated body of the swirl ring and the nozzlecan cooperatively define the plurality of gas flow openings.

In some embodiments, the nozzle retention surface includes a nozzleretention feature located on an external surface of the extensions. Thenozzle retention feature can comprise a groove configured to receive aportion of the nozzle via crimping. In some embodiments, the nozzleretention surface comprises a sloped surface configured to receive aportion of the nozzle via crimping.

In some embodiments, the swirl ring is configured to engage the nozzlevia one of snap fit or threading. In some embodiments, the swirl ring isconfigured to engage the nozzle via crimping.

In some embodiments, the elongated body is molded from a thermoplasticmaterial comprising a polymer formed of ether and ketone molecules. Thethermoplastic material can further comprise one or more additives.

In another aspect, an assembly for an air-cooled plasma arc torch isprovided. The assembly comprises an electrode, a swirl ring molded froma thermoplastic material, a nozzle, and a crown. The swirl ringcomprises a nozzle retention surface at a distal end and a crownretention element at a proximal end. The nozzle is fixedly secured tothe distal end of the swirl ring via the nozzle retention surface, wherethe nozzle includes an exit orifice at a distal end of the nozzle. Thecrown is fixedly secured to the proximal end of the swirl ring via thecrown retention element. The crown is configured to enclose the swirlring at the proximal end. The securement of the swirl ring, the nozzleand the crown creates a chamber in which the electrode is permanentlydisposed and aligned relative to the nozzle.

In some embodiments, the nozzle retention surface comprises a slopedsurface and the nozzle is secured to the distal end of the swirl ring bycrimping at least a portion of the nozzle against the sloped surface.The crimping of the nozzle to the nozzle retention can establish (1) aradial centering of the nozzle exit orifice within the chamber withrespect to a distal end of the electrode to within 0.005 inches, and (2)a longitudinal positioning of the electrode within the chamber betweenthe distal end of the electrode and the nozzle exit orifice during atransferred arc operation of the assembly to within 0.030 to 0.060inches.

In some embodiments, the crown retention element comprises a grooveconfigured to secure the swirl ring by at least one of crimping,threading, or snap fit. The securement of the crown to the swirl ringvia the crown retention element can establish a longitudinal positioningof the electrode within the chamber between a distal end of theelectrode and the nozzle exit orifice during a transferred arc operationof the assembly to within 0.030 to 0.060 inches.

In some embodiments, the assembly further comprises a resilient elementbetween a biasing surface of the crown and the electrode, the resilientelement physically contacting the electrode and imparting a separationforce upon the electrode. The resilient element can pass substantiallyall of a pilot arc current to the electrode when the plasma arc torch isoperated in a pilot arc mode. The crown can comprise a hollow body formaintaining the resilient element substantially therein. In someembodiments, the resilient element comprises at least one of a spring orwire.

In some embodiments, the assembly further comprises an o-ring configuredto substantially surround the proximal end of the swirl ring to seal theswirl ring against a body of the plasma arc torch.

In another aspect, a crown is provided for a contact start plasma arctorch configured for electrical communication with an electrode. Thecrown comprises a substantially hollow body, formed from an electricallyconductive material, configured to receive a resilient element. Thehollow body has a substantially uniform thickness. The crown alsoincludes a biasing surface at a proximal end of the crown for physicallycontacting the resilient element. The crown further includes an interiorcontact surface at the distal end for physically contacting, during atransferred arc mode of the plasma arc torch, a corresponding surface atthe proximal end of the electrode. The contact surface is characterizedby an absence of contact with the corresponding surface of the electrodeduring a pilot arc mode of the plasma arc torch.

In some embodiments, the contact surface is configured to pass at leasta portion of a transferred arc current from the power supply to theelectrode during the transferred arc mode. Additionally, the resilientelement can be configured to pass substantially all of a pilot arccurrent from the power supply to the electrode during the pilot arcmode.

In some embodiments, the crown further includes a retention element forconnection to a swirl ring via one of crimping, snap fit or threading.In some embodiments, the crown further includes at least one vent hole.In some embodiments, the crown further comprises a circular tunnelportion that includes the biasing surface and is configured to house atleast a portion of the resilient element. In some embodiments, the crownfurther comprises a depressed center extending away from the proximalend that includes the contact surface.

In some embodiments, the crown is formed via a stamping process.

In another aspect, a method for aligning a plurality of components in acartridge is provided. The method includes molding a thermoplasticmaterial to form a swirl ring comprising a distal end, a proximal endand a hollow body. The method also includes disposing an electrodeinside of the hollow body of the swirl ring and retaining the electrodeto the cartridge by fixedly securing the nozzle to the distal end of theswirl ring. The method further includes longitudinally aligning theelectrode relative to the nozzle by fixedly securing a crown to theproximal end of the swirl ring, thereby establishing the longitudinalalignment during a transferred arc operation of the cartridge when a gasflow is used to bias the electrode into contact with the crown.

In some embodiments, the method further comprises forming the crown viaa stamping process. In some embodiments, the method further comprisesradially aligning the electrode by restraining a radial motion of theelectrode within the hollow body of the swirl ring.

In some embodiments, the longitudinal alignment comprises restraining alongitudinal motion of the electrode to within a blow-back distancedefined by a distal end of the electrode and an exit orifice of thenozzle during the transferred arc operation.

In some embodiments, fixed securing the nozzle to the distal end of theswirl ring comprises crimping a portion of the nozzle into a retentionsurface on the distal end of the swirl ring.

In another aspect, a consumable cartridge for a plasma arc torch isprovided. The consumable cartridge includes an outer component defininga substantially hollow body, an inner component disposed substantiallywithin the hollow body of the outer component, and a hollow regionbetween the rear portion of the inner component and the outer component.The inner component includes a forward portion configured to axiallysecure and rotatatably engage the outer component to the inner componentand a rear portion substantially suspended within the hollow body of theouter component. The rear portion is axially secured and rotatablyengaged with the outer component via the forward portion. The hollowregion is configured to receive a torch head to enable mating betweenthe rear portion of the inner component and a cathode of the torch head.

In some embodiments, the forward portion of the inner component includesa means for enabling axial securement and rotatable engagement of theouter component thereto. This means for enabling is dimensioned topermit independent rotation of the inner and outer components relativeto each other. In some embodiments, the rear portion of the innercomponent has no means for enabling axial securement and rotatableengagement with the outer component. The axial securing and rotatableengaging of the outer component to the inner component can be by one ofcrimping, snap fitting, frictional fitting or threading.

In some embodiments, the outer component comprises at least one of ashield, an insulating component, a retaining cap or a cap sleeve. Insome embodiments, the inner component comprises at least one of a crown,a swirl ring, an electrode or a nozzle.

In some embodiments, the rear portion of the inner component isconfigured to substantially surround and physically contact at least aportion of the cathode. The rear portion of the inner component cancomprise a cavity configured to receive the at least a portion of thecathode extending into the cartridge. In some embodiments, at least oneof the rear portion of the inner component or the outer componentcomprises at least one thread for engaging the torch head.

In some embodiments, the inner component further comprises one or morefins disposed on an external surface of the inner component. The outercomponent can also comprise one or more fins disposed on an internalsurface of the outer component.

In some embodiments, the outer component provides an electrical path fora pilot arc current of the plasma arc torch.

In another aspect, a cartridge consumable for a plasma arc torch isprovided. The cartridge consumable comprises (i) an outer componentdefining a substantially hollow body, (ii) an inner component,comprising at least an electrode, disposed within the hollow body of theouter component; and (iii) an engagement feature disposed on the innercomponent. The engagement feature is adapted to axially constrain theouter component relative to the inner component while permittingindependent rotation of the inner and outer components relative to eachother.

In some embodiments, the inner component further comprises a crown thatis substantially locked into position upon assembly into the plasma arctorch. A swirl ring can be connected to the outer component via a nozzleof the inner component. The electrode can be disposed within a hollowenclosure defined by the swirl ring and the nozzle. At least one of theswirl ring or the electrode can be a part of the inner component.

In some embodiments, the outer component comprises a metallic retainingcap and an electrically insulative cap sleeve overmolded onto theretaining cap. A shield can be connected to the inner component via theouter component. The shield can be a part of the outer component.

In some embodiments, the cartridge consumable further comprises a hollowregion between the outer component and the inner component. The hollowregion is configured to matingly engage a head of the plasma arc torch.The cartridge consumable can further include a washer located betweenthe outer component and a nozzle of the inner component. The washercomprises one or more cooling channels configured to regulate a gas flowtherethrough.

In yet another aspect, a method of assembling a multi-piece cartridgeconsumable is provided, where the cartridge consumable comprises anouter component and an inner component for installation into a plasmaarc torch. The method includes disposing the inner component within ahollow body of the outer component. The method also includes axiallyrestraining the outer component relative to a forward portion of theinner component while permitting independent rotation of the inner andouter components relative to each other. The method further includessubstantially suspending and radially orienting, by the axialrestraining, a rear portion of the inner component within the hollowbody of the outer component.

In some embodiments, the method further includes installing themulti-piece cartridge consumable into a torch head by disposing thetorch head in a hollow region between the rear portion of the innercomponent and the outer component. The installing can enable physicalmating between a cathode of the torch head and a recess in the rearportion of the inner component. In some embodiments, the method furtherincludes rotating the outer component independent of the inner componentto secure the torch head to the multi-piece cartridge consumable.

In some embodiments, the method further includes assembling the innercomponent of the multi-piece cartridge, which comprises disposing anelectrode inside of a hollow body of a swirl ring, retaining theelectrode within the hollow body by fixedly securing a nozzle to adistal end of the swirl ring, and fixedly securing a crown to a proximalend of the swirl ring. In some embodiments, the method further includesassembling the outer component of the multi-piece cartridge, whichcomprises over-molding an insulative cap sleeve onto a retaining cap andfixedly connecting a shield to the cap sleeve.

In some embodiments, the method further includes radially aligning theinner component with respect to the outer component by one or more finsdisposed on a surface of at least one of the inner or outer component.

In yet another aspect, a crown for a plasma arc torch is provided. Thecrown includes a body defining a proximal and a distal end, the bodyincluding an electrically conductive material and at least one raisedfeature at the proximal end of the body. The raised feature adapted toactivate a consumable sensor inside of the plasma arc torch. The crowncan also include a biasing surface at the proximal end of the body forphysically contacting a resilient element.

In some embodiments, the crown further includes a contact surface at thedistal end of the body for physically contacting, during a transferredarc mode of the plasma arc torch, a corresponding surface of anelectrode. The at least one raised feature is configured to activate theconsumable sensor by pressing against the consumable sensor uponinstallation of the crown into the plasma arc torch, thereby permittinga flow of electrical current through one of (i) the biasing surface tothe resilient element during a pilot arc mode of the plasma arc torch or(ii) the contact surface to the electrode during the transferred arcmode.

In some embodiments, the body of the crown is substantially hollow andis configured to retain the resilient element between the biasingsurface and the electrode. The body of the crown can have asubstantially uniform thickness.

In some embodiments, the body of the crown defines a cavity configuredto receive at least a portion of a cathode of the plasma arc torch. Thecontact surface can be located in an interior surface of the crown bodydefining the cavity.

In yet another aspect, an inner cartridge consumable of a multi-piececartridge consumable for a plasma arc torch is provided. The innercartridge consumable includes a crown including (i) a recess about acentral axis shaped to receive at least a portion of a cathode of theplasma arc torch and (ii) a protrusion region surrounding the recessabout the central axis shaped to house a spring component. The innercartridge consumable also includes a swirl ring defining a distal endand a proximal end. The swirl ring is fixedly connected to the crown atthe proximal end of the swirl ring. The inner cartridge consumablefurther includes a nozzle fixedly connected to the swirl ring at thedistal end of the swirl ring and an electrode disposed in a chamberdefined within the fixed connection of the crown, the swirl ring and thenozzle.

In some embodiments, the the crown physically contacts the cathode andis disposed between the cathode and the electrode. In some embodiments,the crown defines an opening to allow at least a portion of the cathodeto pass therethrough to physically contact the electrode in atransferred arc mode of operating the plasma arc torch. The recess ofthe crown can be configured to permit the cathode to extend within theinner cartridge consumable.

In some embodiments, the protrusion region of the crown is adapted toactivate a consumable sensor inside of the plasma arc torch. In someembodiments, a portion of the swirl ring is adapted to extend through anopening in the crown to activate a consumable sensor inside of theplasma arc torch.

In some embodiments, the inner cartridge consumable is substantiallyconductive. In some embodiments, the spring component is adapted toextend longitudinally and substantially parallel to the cathode uponinstallation of the multi-piece cartridge consumable in the plasma arctorch.

In some embodiments, the inner cartridge consumable further comprises aretention feature disposed on a surface of the inner cartridgeconsumable for rotationally engaging and axially securing an outercartridge consumable of the multi-piece cartridge consumable. Theretention feature can be disposed on a surface of at least one of thenozzle or the swirl ring.

In yet another aspect, a method of installing a cartridge into a plasmaarc torch is provided. The method includes assembling an inner componentof the cartridge including disposing an electrode inside of a hollowbody of a swirl ring that includes a distal end and a proximal end,capturing the electrode within the swirl ring by fixedly securing anozzle at the distal end of the swirl ring, and fixedly securing a crownto the proximal end of the swirl ring. The method also includes securinga torch head to the cartridge that includes the inner component and anouter component, and depressing, by at least one raised feature, aconsumable sensor inside of a torch head of the plasma arc torch. Themethod further includes establishing an electrical current flow pathfrom a source of power through the torch head and to the cartridge basedon the depressing.

In some embodiments, the method further includes positioning the crownbetween a cathode of the torch head and the electrode and radially andlongitudinally aligning the cathode, the crown and the electrode. Themethod can further include enabling physical mating between the cathodeand a recess of the crown. The method can further include enablingphysical contact between the cathode and the electrode via an opening ofthe crown during a transferred mode operation of the plasma arc torch.

In some embodiments, the method further includes physically contacting,by a biasing surface at the proximal end of the crown, a resilientelement and physically contacting, by a contact surface at the distalend of the crown, a corresponding surface of the electrode during atransferred arc mode of the plasma arc torch. The method can furtherinclude permitting a flow of electrical current in the electricalcurrent flow path through one of (i) the biasing surface to theresilient element during a pilot arc mode of the plasma arc torch or(ii) the contact surface to the electrode during the transferred arcmode.

In some embodiments, the method further includes disposing the innercomponent within a hollow body of the outer component and axiallyrestraining the inner component relative to the outer component whilepermitting independent rotation of the inner and outer componentsrelative to each other. The method can further include substantiallysuspending and radially orienting, by the axial restraining, a rearportion of the inner component within the hollow body of the outercomponent. The method can further include radially aligning the innercomponent with respect to the outer component by one or more finsdisposed on a surface of at least one of the inner or outer component.

In some embodiments, the raise feature is disposed on the crown or theswirl ring.

In another aspect, the invention features a portion of a consumablecartridge for a plasma arc torch. The portion includes a cap assemblyincluding a retaining cap and a cap sleeve. The retaining cap isconstructed from a conductive material and the cap sleeve is constructedfrom an insulator material. The cap assembly defines a proximal end anda distal end disposed along a longitudinal axis of the plasma arc torch.The portion also includes a shield comprising a body defining asubstantially hollow portion. The body has a proximal end and a distalend aligned along the longitudinal axis, and the distal end comprises ashield exit orifice. The portion further includes an insulator ringconstructed from an electrically insulating material. The insulator ringincludes an exterior surface configured to irremovably affix to at leasta portion of the proximal end of the body of the shield and an interiorsurface configured to irremovably affix to an exterior surface of thedistal end of the cap assembly. The irremovable affixation between theinsulator ring and the shield and between the cap assembly and theinsulator ring irremovably secures the shield to the cap assembly of theconsumable cartridge.

In some embodiments, the insulator ring maintains electrical insulationbetween the shield and the cap assembly. In some embodiments, theinterior surface of the insulator ring is irremovably affixed to theexterior surface of the distal end of the cap assembly by at least onecircumferential protrusion on the exterior surface of the cap assemblyconfigured to hold the insulator ring in place against the cap assembly.The at least one circumferential protrusion can be produced by a stakingprocess.

In some embodiments, the exterior surface of the insulator ring isirremovably affixed to the proximal end of the shield via crimping. Theportion of the consumable cartridge can further include at least onepiercing disposed on the proximal end of the body of the shield, wherethe at least one piercing is adapted to lock the insulator ring in placevia the crimping. In some embodiments, a plurality of piercing s areformed during the crimping, where the plurality of piercings are spacedin two rows around the proximal end of the body of the shield. In someembodiments, a first row of the plurality of piercing s is locatedproximal to a proximal edge of the insulator ring and a second row ofthe plurality of piercings is located distal to a distal edge of theinsulator ring. The proximal and distal edges the insulator ring areadapted to be spaced apart longitudinally along the longitudinal axis.

In some embodiments, the electrically insulating material of theinsulator ring is Vespel®. In some embodiments, the electricallyinsulating material of the insulator ring comprises a thermoplasticmaterial that includes a polymer formed of ether and ketone molecules.

In another aspect, the invention features a method of forming at least aportion of a consumable cartridge of a plasma arc torch. The methodincludes providing a shield comprising a body having a substantiallyhollow portion, a proximal end, and a distal end comprising a shieldexit orifice. The method also includes providing a cap assemblyincluding a retaining cap and a cap sleeve over-molded onto at least aportion of the retaining cap. The retaining cap comprises an exteriormounting surface disposed at a distal end. The method further includesirremovably securing an insulator ring onto the exterior mountingsurface of the cap assembly while radially aligning the insulator ringwith the cap assembly, and irremovably securing the shield to anexterior surface of the insulator ring by crimping at least a portion ofthe proximal end of the shield body to the insulator ring, whileradially aligning the shield with the insulator ring.

In some embodiments, the method further comprises forming the shield viastamping. In some embodiments, the method further comprises maintainingelectrical insulation between the cap assembly and the shield.

In some embodiments, irremovably securing the insulator ring to theexterior mounting surface of the cap assembly comprises staking theinsulator ring to the cap assembly by forming at least onecircumferential protrusion on the exterior mounting surface to prevent alongitudinal movement of the insulator ring. In some embodiments,irremovably securing the shield to the insulator ring comprises formingtwo rows of piercings during crimping around the proximal end of theshield body. A first row of the piercings are crimped inward proximal toa proximal edge of the insulator ring and a second row of the piercingsare crimped inward distal to a distal edge of the insulator ring. Theproximal and distal edges of the insulator ring are spaced apartlongitudinally relative to each other.

In another aspect, the invention features a method of manufacturing acap assembly for a plasma arc torch. The method includes stamping aconductive material blank to form a cylindrical body that issubstantially hollow. The hollow body includes a distal portion and aproximal portion. The stamping is adapted to form at least one discretethread disposed in the hollow body and extends circumferentially aroundthe proximal portion. The method also includes over-molding an insulatormaterial onto an exterior surface of the conductive hollow body.

In some embodiments, the at least one discrete thread is configured toengage a complementary thread on a corresponding component of the plasmaarc torch. The corresponding component can comprise a torch body. Insome embodiments, the at least one discrete thread consists of threediscrete threads. In some embodiments, the at least one thread forms aconcave portion relative to the exterior surface of the conductivehollow body. The over-molding of the insulator material can fill in theconcave portion of the at least one thread and stiffens the at least onethread.

In some embodiments, the insulator material comprises at least one of aplastic material or a thermoplastic material.

In some embodiments, the cap assembly is a part of an integratedcartridge of the plasma arc torch. The distal portion of the conductivehollow body is adapted to fixedly attach to at least one of a shield ora nozzle to form a portion of the integrated cartridge.

In yet another aspect, the invention features a method of forming atleast a portion of a consumable cartridge of a plasma arc torch. Themethod includes providing a cap assembly including a retaining cap and acap sleeve over-molded onto at least a portion of the retaining cap. Theretaining cap comprises an exterior mounting surface disposed at adistal end. The method also includes positioning an insulator ring ontothe exterior mounting surface of the cap assembly at the distal end ofthe cap assembly, where the insulator ring comprises a proximal end anda distal end. The method further includes sliding the insulator ring ina proximal direction along the cap assembly to abut a feature of the capassembly that prevents further proximal motion of the insulator ring,and staking a metallic surface of the cap assembly at the distal end ofthe insulator ring to irremovably affix the insulator ring to the cap.In some embodiments, the abutting feature is a portion of the cap sleeveof the cap assembly.

In another aspect, the present invention features an adapter for aplasma arc torch comprising a torch body. The adapter includes a bodydefining a longitudinal axis between a proximal end and a distal end andat least one protruding portion extending from the proximal end of thebody. The at least one protruding portion is configured to be insertedinto a cavity of the torch body to physically engage a switch inside ofthe cavity. The engagement of the switch adapted to indicateinstallation of a consumable component in the plasma arc torch.

In some embodiments, the body of the adapter is detached from theconsumable component. In some embodiments, the body of the adapter iscoupled to the consumable component. In some embodiments, the body ofthe adapter comprises an outer portion and an inner portion retractablerelative to the outer portion, where the inner portion is configured totranslate longitudinally within the outer portion to physically engagethe switch. In some embodiments, the body of the adapter is configuredto (i) physically contact the consumable component at the distal end and(ii) physically contact the switch at the proximal end via theprotruding portion.

In some embodiments, the consumable component is a swirl ring. In someembodiments, the body of the adapter is a crown attached to a proximalend of a swirl ring. The at least one protruding portion can be adaptedto extend from the swirl ring, through an opening in the crown, tophysically engage the switch. In some embodiments, the consumablecomponent is a consumable cartridge. The consumable cartridge cancomprise a swirl ring body, and the adapter body can be integrated witha proximal end of the swirl ring body such that the at least oneprotruding portion of the adapter comprises a lip portion of the swirlring body configured to physically engage the switch.

In some embodiments, the at least one protruding portion extends alongthe longitudinal axis to physically engage the switch. In someembodiments, the at least one protruding portion extends in a lateraldirection perpendicular to the longitudinal axis to physically engagethe switch. In some embodiments, the at least one protruding portioncomprises one or more fins that extend longitudinally along thelongitudinal axis or laterally perpendicular to the longitudinal axis tophysically engage the switch.

In some embodiments, the at least one protruding portion is dimensionedto fit radially between a cathodic body and a circular wall of thecavity within the torch body, such that the at least one protrudingportion is adapted to physically engage the switch disposed in thecavity upon the insertion. The body of the adapter can be translatablebetween the consumable component and the cathodic body up to apredetermined distance. In some embodiments, the protruding portion isconfigured to engage the switch by pressing against the switch uponinstallation of the adapter into the plasma arc torch, therebypermitting a flow of electrical current to the consumable component toenable operation of the plasma arc torch.

In some embodiments, the adapter body defines an inner portion and anouter portion. The adapter further comprises a set of torch mountthreads located on the proximal end of the body configured to engage thetorch body, a set of consumable mount threads located on the distal endof the body configured to engage the consumable component, and acathodic element extending along the longitudinal axis, the cathodicelement located in the inner portion of the adapter body. In someembodiments, the set of torch mount threads is disposed on an interiorsurface on the outer portion of the adapter body. In some embodiments,the set of consumable mount threads is disposed on an exterior surfaceon the outer portion of the adapter body. In some embodiments, thecathodic element is adapted to be in electric communication with acathode of the plasma arc torch to convey an electrical current from thecathode to the consumable component. In some embodiments, the at leastone protruding portion of the adapter is located in the inner portion ofthe adapter body radially between the cathodic element and the outerportion.

In yet another aspect, the present invention features an adapter for aplasma arc torch that includes a consumable component and a torch body.The adapter includes a body defining a longitudinal axis between aproximal end and a distal end. The body comprises an inner portion andan outer portion. The adapter includes a set of torch mount threadslocated on the proximal end of the body on an interior surface of theouter portion. The set of torch mount threads are configured to engagethe torch body. The adapter also includes a set of consumable mountthreads located on the distal end of the body on an exterior surface ofthe outer portion. The set of consumable mount threads configured toengage the consumable component. The adapter additionally includes anelectrically conductive cathodic element extending along thelongitudinal axis. The cathodic element is located in the inner portionof the adapter body. The adapter further includes a switch actuatorlocated at the proximal end of the body. The switch actuator isconfigured to be inserted into a cavity of the torch body to indicate apresence of the consumable component within the plasma arc torch. Insome embodiments, the switch actuator is positioned radially between thecathodic element and the outer portion.

In yet another aspect, the present invention features a method fordetecting a presence of a consumable in a plasma arc torch that includesa torch body. The method includes providing an adapter having a bodydefining a proximal end and a distal end. The body has at least oneprotruding portion extending from the proximal end. The method alsoincludes inserting the protruding portion of the adapter into a cavityof the torch body and physically engaging, by the protruding portion ofthe adapter, at least one consumable sensing pin within the cavity toindicate the presence of the consumable.

In some embodiments, the method further comprises physically contacting,by the distal end of the adapter, the consumable. In some embodiments,the method further comprises initiating an electrical current flow by apower supply of the plasma arc torch permitted by the physicalengagement of the consumable sensing pin by the adapter and conductingthe electrical current flow from the cathodic body to the consumable. Insome embodiments, the method further comprises translating theprotruding portion of the adapter to depress the consumable sensing pin.

In some embodiments, the consumable sensing pin is located radiallybetween a cathodic body of the plasma arc torch and a circular portionof the cavity, where the cathodic body is centered within the cavity. Insome embodiments, the consumable comprises a consumable cartridge thatincludes an electrode disposed inside of a hollow body of a swirl ring.

In some embodiments, the adapter is constructed from an electricallyconductive material. In some embodiments, the adapter is detached fromthe consumable. In some embodiments, the adapter is integrated with theconsumable.

In some embodiments, the protruding portion extends longitudinally alonga longitudinal axis to physically contact the consumable sensing pin. Insome embodiments, the protruding portion extends in a lateral directionperpendicular to a longitudinal axis to physically contact theconsumable sensing pin.

In yet another aspect, the present invention features a method fordetecting a presence of a consumable in a plasma arc torch that includesa torch head having (i) a cavity, (ii) a cathode disposed in the cavity,and (iii) a consumable sensing pin disposed in the cavity. The methodincludes providing an adapter having a body defining a proximal end anda distal end and at least one protruding portion extending from theproximal end of the body, and inserting the protruding portion of theadapter into the cavity such that the protruding portion is nestedradially between the cathode and a wall of the cavity. The method alsoincludes installing the consumable inside of the plasma arc torch andphysically activating, by the protruding portion of the adapter, theconsumable sensing pin in the cavity to indicate the presence of theconsumable. The method further includes permitting, based on thephysical activation, a flow of electrical current from the cathode tothe consumable to enable operation of the plasma arc torch.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of the invention described above, together with furtheradvantages, may be better understood by referring to the followingdescription taken in conjunction with the accompanying drawings. Thedrawings are not necessarily to scale, emphasis instead generally beingplaced upon illustrating the principles of the invention.

FIG. 1 is a cross-sectional view of an exemplary cartridge for a plasmaarc torch, according to an illustrative embodiment of the invention.

FIG. 2 is an isometric view of the electrode of the cartridge of FIG. 1, according to an illustrative embodiment of the invention.

FIG. 3 is an isometric view of the nozzle of the cartridge of FIG. 1 ,according to an illustrative embodiment of the invention.

FIGS. 4 a and 4 b are isometric and profile views of the swirl ring ofthe cartridge of FIG. 1 , respectively, according to an illustrativeembodiment of the invention.

FIGS. 5 a and 5 b are isometric and sectional views of another swirlring design compatible with the cartridge of FIG. 1 , respectively,according to an illustrative embodiment of the invention.

FIG. 6 is a sectional view of the swirl ring of the cartridge of FIG. 1with the electrode aligned within the swirl ring and illustrating anexemplary gas flow opening.

FIGS. 7 a and 7 b are isometric and sectional views of the crown of thecartridge of FIG. 1 , respectively, according to an illustrativeembodiment of the invention.

FIG. 8 is an exemplary shield design compatible with the cartridge ofFIG. 1 , according to an illustrative embodiment of the invention.

FIG. 9 is an exploded view of the cartridge of FIG. 1 , according to anillustrative embodiment of the invention.

FIG. 10 is a sectional view of another exemplary cartridge for a plasmaarc torch, according to an illustrative embodiment of the invention.

FIG. 11 is an exemplary configuration of the retaining cap of thecartridge of FIG. 10 , according to an illustrative embodiment of theinvention.

FIGS. 12 a and 12 b are sectional and exterior profile views,respectively, of an exemplary cap sleeve overmolded onto the retainingcap of FIG. 11 , according to an illustrative embodiment of theinvention.

FIG. 13 is an exemplary configuration of the insulator component, whichcan be a part of the outer component of the cartridge of FIG. 10 ,according to an illustrative embodiment of the invention.

FIGS. 14 a-c are various views of the insulator component of FIG. 13fixedly secured to the cap sleeve and the retaining cap, according to anillustrative embodiment of the invention.

FIG. 15 is an exemplary configuration of the shield that can be a partof the outer component of the cartridge of FIG. 10 , according to anillustrative embodiment of the invention.

FIG. 16 is another exemplary shield that is compatible with thecartridge of FIG. 10 , according to an illustrative embodiment of theinvention.

FIG. 17 is an exemplary configuration of the nozzle of the cartridge ofFIG. 10 , according to an illustrative embodiment of the invention.

FIG. 18 is cross-sectional view of an assembly comprising the nozzle,the retaining cap and the shield of the cartridge of FIG. 10 , accordingto an illustrative embodiment of the invention.

FIGS. 19 a-c are various views of another exemplary configuration of theswirl ring of the cartridge of FIG. 10 , according to an illustrativeembodiment of the invention.

FIGS. 20 a and b are exemplary configurations of the crown of thecartridge of FIG. 10 , according to an illustrative embodiment of theinvention.

FIG. 21 shows an exemplary insert between the nozzle and the outercomponent of the cartridge of FIG. 10 to control gas flow, according toan illustrative embodiment of the invention.

FIG. 22 shows an exemplary plasma arc torch including the cartridge ofFIG. 10 and a torch head, according to an illustrative embodiment of theinvention.

FIG. 23 is an exemplary configuration of the torch head of FIG. 22 ,according to an illustrative embodiment of the invention.

FIGS. 24 a and b show exemplary pilot arc current flow paths through thecartridge of FIG. 10 during pilot arc initiation, according to anillustrative embodiment of the invention.

FIG. 25 shows an exemplary transferred arc current flow path through thecartridge of FIG. 10 during transferred arc mode of torch operation,according to an illustrative embodiment of the invention.

FIG. 26 is an exemplary gas flow path through the cartridge of FIG. 10 ,according to an illustrative embodiment of the invention.

FIG. 27 is an exploded view of the cartridge of FIG. 10 , according toan illustrative embodiment of the invention.

FIGS. 28 a and 28 b show an exemplary assembly of multiple componentsfor forming at least a portion of the cartridge of FIG. 10 , accordingto some embodiments of the present invention.

FIG. 29 shows an exemplary interface formed between the cap assembly andthe insulator ring of FIGS. 28 a and 28 b using a staking process,according to some embodiments of the present invention.

FIG. 30 shows an exemplary interface formed between the shield and theinsulator ring of FIGS. 28 a and 28 b using a crimping process,according to some embodiments of the present invention.

FIGS. 31 a and 31 b illustrate an exemplary process for forming theassembly of FIGS. 28 a and 28 b to produce a portion of the cartridge ofFIG. 10 , according to some embodiments of the present invention.

FIG. 32 illustrates an exemplary method for manufacturing a cap assemblyfor the cartridge of FIG. 10 , according to some embodiments of thepresent invention.

FIG. 33 shows an exemplary configuration of an adapter, according tosome embodiments of the present invention.

FIG. 34 shows another exemplary configuration of an adapter, accordingto some embodiments of the present invention.

FIG. 35 shows an exemplary arrangement of the adapter of FIG. 34 insideof a plasma arc torch, according to some embodiments of the presentinvention.

FIGS. 36 a-c show profile, side, and top views, respectively, of anexemplary consumable component that integrates the adapter of FIG. 34with a swirl ring portion, according to some embodiments of the presentinvention.

FIG. 37 shows yet another exemplary configuration of an adapter,according to some embodiments of the present invention.

FIG. 38 shows an exemplary process for detecting the presence of aconsumable component in a plasma arc torch using an adapter, accordingto some embodiments of the present invention.

DETAILED DESCRIPTION

FIG. 1 is a cross-sectional view of an exemplary cartridge 100 for aplasma arc torch, according to an illustrative embodiment of theinvention. As shown, the cartridge 100 includes an end cap 106 (e.g., acrown), a swirl ring 102, an electrode 104, and a nozzle 108 orientedsubstantially symmetrically about the longitudinal axis A. The cartridge100 can additionally include a resilient element 122 and/or a sealingdevice 150. The cartridge 100 can use a blow-back contact startingmechanism for contact starting the plasma arc torch upon assembly intothe torch. Specifically, the electrode 104 can be a spring-forwardelectrode, which means that the resilient element 122 (e.g., a spring)can exert a separating force on the proximal end 124 of the electrode104 to bias the electrode 104 away from the end cap 106 and toward thenozzle 108.

FIG. 2 is an isometric view of the electrode 104, according to anillustrative embodiment of the invention. As shown, the electrode 104includes a set of spiral-shaped fins 114 for directing a gas flow andfacilitating cooling of the cartridge 100. An emissive insert 142 (i.e.,emitter), as shown in FIG. 1 , can be disposed in the distal end 125 ofthe electrode 104 so that an emission surface is exposed. The insert 142can be made of hafnium or other materials that possess suitable physicalcharacteristics, including corrosion resistance and a high thermionicemissivity. Forging, impact extrusion, or cold forming can be used toinitially form the electrode 104 prior to finish machining thecomponent.

The nozzle 108 can be spaced from the distal end 125 of the electrode104 and define, in relation to the electrode 104, a plasma chamber 140.FIG. 3 is an isometric view of the nozzle 108, according to anillustrative embodiment of the invention. The nozzle 108 includes acentrally-located exit orifice 144 for introducing a plasma arc, such asan ionized gas jet, to a workpiece (not shown) to be cut.

In some embodiments, the swirl ring 102 has a set of radially spaced gasflow openings 136 configured to impart a tangential velocity componentto a gas flow for the plasma arc torch, causing the gas flow to swirl.This swirl creates a vortex that constricts the arc and stabilizes theposition of the arc on the insert 142. In some embodiments, the sealingdevice 150, such as an o-ring, can be located on an external surface ofthe swirl ring 102 at its proximal end 112 to engage an internal surfaceof the plasma arc torch body (not shown) when the the cartridge 100 isinstalled into the plasma arc torch body. The sealing device 150 isconfigured to provide a leak-proof seal of fluids (e.g., gases) betweenthe cartridge 100 and the plasma arc torch body at that location.

FIGS. 4 a and 4 b are isometric and profile views of the swirl ring 102of the cartridge 100 of FIG. 1 , respectively, according to anillustrative embodiment of the invention. As shown, the swirl ring 102can be defined by a substantially hollow, elongated body 103 having thedistal end 110 and the proximal end 112 along the longitudinal axis A.The distal end 110 of the swirl ring 102 is characterized as the endthat is closest to a workpiece when operating the cartridge 100 withinthe plasma arc torch, and the proximal end 112 is the opposite of thedistal end 110 along the longitudinal axis A. In some embodiments, thehollow body 103 of the swirl ring 102 is dimensioned to receive theelectrode 104 and substantially extend over the length of the electrode104 along the longitudinal axis A. The inner wall of the the swirl ring102 can thus radially align the electrode 104 by limiting a radialmovement of the electrode 104. An interface 118 can be formed betweenthe distal end 110 of the swirl ring 102 and the nozzle 108 to join thetwo consumable components together as a part of the cartridge 100.Another interface 120 can be formed between the proximal end 112 of theswirl ring 102 and the end cap 106 to join the two consumable componentstogether as a part of the cartridge 100. In general, the interface 118and/or the interface 120 form a chamber in which the electrode 104 ispermanently disposed and aligned (longitudinally and radially) relativeto the nozzle 108 and the end cap 106.

In some embodiments, the one or more gas flow openings 136 of the swirlring 102 are disposed about the distal end 110 of its elongated body103, such as around a circumference of its distal end 110. In someembodiments, the one or more gas flow openings 136 are molded. Each gasflow opening 136 can extend from an interior surface to an exteriorsurface of the elongated body 103 and is oriented to impart a swirlingmotion relative to the axis A to the gas (e.g., air) flowingtherethrough. Each gas flow opening 136 can be circular or non-circular(e.g., rectangular, squared and/or square-cornered) in geometry. In someembodiments, the gas flow openings 136 have substantially uniformdimensions. In some embodiments, as shown in FIGS. 4 a and 4 b , the gasflow openings 136 are at least partially defined by slots 202 at thedistal end 110 of the elongated body 103 of the swirl ring 102. Thesegas flow slots 202 are formed by a plurality of extensions 204 spacedapart at regular or non-regular intervals around the circumference ofthe distal end 110, where each slot 202 is situated between a pair ofthe extensions 204. Upon the swirl ring 102 being securely affixed tothe nozzle 108, the slots 202 are closed off by the proximal end of thenozzle 108 to create bounded holes. Hence, each gas flow opening 136 canbe a two-piece composite opening cooperatively defined by the nozzle 108and the swirl ring 102.

In some embodiments, to form the interface 118 between the swirl ring102 and the nozzle 108, the swirl ring 102 can include a nozzleretention surface 216 (e.g., interior and/or exterior surface) of theelongated body 103 for securely attaching the nozzle 108 at its distalend 110. In one example, as illustrated in FIGS. 4 a and b , the nozzleretention surface 216 can be a feature, such as one or more grooveslocated on the external surface of the elongated body 103, such as onthe extensions 204. The nozzle retention surface 216 can capture thenozzle 108 through one of snap fit, crimping, or threading to form theinterface 118. In a crimping example, a portion of the nozzle 108 can becrimped against and into the groove 216 to securely affix the nozzle 108to the swirl ring 102. Alternatively, a similar retention surface can bedisposed on the nozzle 108 to retain the swirl ring 102 thereto. Othermanufacturing and assembly options are available and viable to connectthe two components. For example, the nozzle 108 can be over-molded ontothe swirl ring 102 to form the interface 118.

FIGS. 5 a and b are isometric and sectional views of another swirl ring702 compatible with the cartridge 100 of FIG. 1 , respectively. Asshown, the swirl ring 702 is substantially similar to the swirl ring 102except that the nozzle retention surface 716 of the swirl ring 702comprises a sloped surface at a tapered angle relative to thelongitudinal axis A. The sloped surface 716 can be adapted to capturethe nozzle 108 through one of snap fit, crimping, or threading to formthe interface 118 of FIG. 1 .

In some embodiments, as shown in FIGS. 4 a and b , to form the interface120 between the swirl ring 102 and the end cap 106, the swirl ring caninclude a cap retention feature 230 located on a surface (e.g., interiorand/or exterior surface) of the elongated body 103 for securelyretaining the end cap 106 at its proximal end 112. The cap retentionfeature 230 can be one or more grooves that capture the end cap 106through one of snap fit, crimping, or threading to form the interface120. For example, a portion of the end cap 106 can be crimped into thegroove(s) 230 to securely affix the end cap 106 to the swirl ring 102.In some embodiments, as shown in FIGS. 1 and 4 b, a lip portion 232 ofthe proximal end 112 of the swirl ring 102 is inserted inside of the endcap 106 after the two components are coupled together. Alternatively, asimilar retention feature can be disposed about the end cap 106 to jointhe swirl ring 102. Other manufacturing and assembly options areavailable and viable to connect the two components. For example, the endcap 106 can be over-molded onto the swirl ring 102 to form the interface120. A similar cap retention feature 730 can be located on a surface ofthe swirl ring 702 of FIGS. 5 a and b and provide substantially the samefunction as the cap retention feature 230.

In general, each of the retention surfaces/elements 216, 230 of FIGS. 4a and b simplifies alignment of the parts in the cartridge 100 incomparison to an operator having to perform alignment of individualcomponents without any structural guidance. In some embodiments, thelocking of the swirl ring 102 to the nozzle 108 at the interface 118 viathe retention element 216 aligns the two components relative to eachother and further retains the electrode 104 in the chamber formed by thelocking of the swirl ring 102 and the nozzle 108. The inner wall of theswirl ring 102 can radially align the electrode 104 such that there is arelatively small gap between the inner wall of the swirl ring 102 andthe radial fins 114 of the electrode 104, thereby limiting a radialmotion of the electrode 104. This thus establishes a radial centering ofthe nozzle exit orifice 144 with respect to the distal end 125 of theelectrode 104 within the chamber, such as within a tolerance of about0.005 inches. In some embodiments, the locking of the swirl ring 102 tothe end cap 106 at the interface 120 via the retention element 230aligns the two components relative to each other and furtherlongitudinally aligns the electrode 104 in the chamber. For example,after the swirl ring 102 and the end cap 106 are joined, the depth ofthe depressed center 304 of the end cap 106 controls how far back theelectrode 104 can move longitudinally toward the proximal end 124 inrelation to the nozzle 108 during a transferred arc mode (e.g., when agas flow is used to bias the electrode 104 into contact with the end cap106), such as within a blow-back distance of 0.02 to 0.12 inches. Thelocking of the swirl ring 102 to the end cap 106 at the interface 120via the retention element 230 also secures the resilient element 122within the cartridge 100 while accurately positioning the resilientelement 122 relative to the proximal end 124 of the electrode 104. Inaddition, the joining of the nozzle 108 to the swirl ring 102 helps todefine the longitudinal motion of the electrode 104 to within theblow-back distance between the distal end 125 of the electrode 104 andthe nozzle exit orifice 144 during the transferred arc operation. Suchrestraint on the longitudinal motion of the electrode 104 promotesaccuracy and repeatability of plasma arc initiation in torch operations.Similarly, each of the retention surfaces/elements 716, 730 of FIGS. 5 aand b simplifies alignment of the parts in the cartridge 100 uponassembly of the swirl ring 702 into the cartridge 100.

In some embodiments, the gas flow openings 136 of the swirl ring 102 aresuitably shaped and dimensioned to enhance swirling of a gas flowtherethrough. FIG. 6 is a sectional view of the swirl ring 102 of thecartridge 100 of FIG. 1 with the electrode 104 radially aligned withinthe swirl ring 102 and illustrating an exemplary gas flow opening 136.

As shown, the swirl ring 102 and the electrode 104 have a shared center602. Width W represents the curved axial width of each gas flow opening136 (only one gas flow opening is shown). Length R represents theaverage distance (radius) between the center of the electrode 104 andthe radius of the annular space between the exterior of the electrodebody and the inner wall of the swirl ring 102, as measured from theshared center 602. In some embodiments, the W/R ratio is less than about0.5. This value allows a gas flow entering a gas flow opening 136 toimpinge somewhat perpendicularly on surface of the electrode 104,increasing gas turbulence and enhancing electrode cooling. In contrast,a traditional gas flow opening design has a W/R ratio of about 1.0,which causes a gas to impinge at most tangentially relative to a surfaceof the electrode 104. The substantial perpendicular impingement (asopposed to the tangential impingement) generates more flow distribution,more uniform gas flow swirling, and better cooling of the electrode 104.In some embodiments, the life of the electrode 104 is extended by 25%when the W/R ratio is less than about 0.5. This design ratio isapplicable to gas flow openings 136 represented by slots 202 molded atthe distal end 110 of the swirl ring 102 or by enclosed holes (notshown) formed, molded, or drilled into the distal end 110.

In some embodiments, only one row of gas flow openings 136 is disposedaround the distal end 110 of the swirl ring 102. For example, one row oftwelve gas flow openings 136 can be disposed symmetrically about theswirl ring 102. In contrast, traditional swirl ring designs have two ormore rows (layers) of gas flow openings, with some traditional swirlrings having eighteen openings per row. Due to the reduced number of gasflow openings 136 in the present design, the width W of individual gasflow openings 136 is increased to generate the same gas flow swirl forceand maintain the same overall cross-sectional area of the gas flowopenings 136 combined in comparison to the traditional designs. Inaddition, for each gas flow opening 136, the offset O between theopening 604 in the inner wall of the swirl ring 102 and the opening 606on the outer wall of the swirl ring 102 is reduced (e.g., to about lessthan or equal to about 0.040 inches) whereas such an offset associatedwith a gas flow opening of a traditional swirl ring design is larger(e.g., about 0.12 inches) In general, reducing the number of gas flowopenings 136, coupled with locating the openings 136 on a single row,simplifies manufacturing cycle time, reduces material cost, and is morecompatible with an injection molding approach for manufacturing theswirl ring 102. The gas flow opening design described with respect tothe swirl ring 102 can also be applied to the swirl ring 702 of FIGS. 5a and b.

In some embodiments, the swirl ring 102 or 702 is manufactured throughinjection molding of one or more high-temperature thermoplasticmaterials comprising a polymer formed of ether and ketone molecules(e.g., ether ketone based compounds), such as polyetheretherketone(PEEK), polyaryletherketone (PAKE), polyetherketoneketone (PEKK),polyetherketoneetherketone-ketone (PEKEKK) and variants thereof.Exemplary thermoplastic materials also include polyamide-imide (PAI),polyetherimide (PEI), and/or polytetrafluoroethylene (PTFE). In someembodiments, properties associated with suitable thermoplastic materialsfor the invention have a glass transition temperature (Tg) of greaterthan about 320 Fahrenheit, a coefficient of linear thermal expansion(CLTE) of less than about 22 micro-inch/inch-Fahrenheit below Tg, a CLTEof less than about 55 micro-inch/inch-Fahrenheit above Tg, a meltingpoint of greater than about 720 Fahrenheit, and/or a dielectric strengthof greater than about 480 kilo-volt/inch. The use of thermoplastics tomanufacture swirl rings reduces cartridge cost in comparison to, forexample, Vespel™, Torlon, Celazole or Phenolic compounds or otherthermal-set plastics, which are materials currently used to manufactureswirl rings, but are comparatively more expensive to obtain anddifficult to use. However, it is known that thermoplastics haveoperating temperatures that are lower than thermos-set Vespel™, whichcan potentially impact the integrity of swirl rings and electrode lifein general. To resolve the high temperature performance issues, theswirl ring 102 or 702 can be made from thermoplastic resins having oneor more fortifying additives to provide the desired thermal resistanceand/or thermal conductivity, thus enabling effective use ofthermoplastic material(s) in cartridges and/or swirl rings. Exemplaryfortifying additives include glass fibers, minerals, boron nitride (BN),Cubic BN and/or Vespel™ particles. As an example, the materialpolymide/polyetheretherketone (PI/PEEK), a heat resistant material thatcan include about 50% recycled Vespel™ particles, can be used tomanufacture the swirl ring 102 or 702. In addition, the swirl ring 102or 702 is positioned in such a location in the cartridge 100 that itavoids exposure to the highest operating temperatures during torchoperation. Thus, in practice, using a thermoplastic material tomanufacture the swirl ring 102 is unlikely to affect the integrity ofthe swirl ring 102 or 702. Furthermore, when the electrode 104experiences an end-of-life event, which is also the end of life of thecartridge 100, the plastic material melts, which does not affect thecutting operation during the consumable life. In contrast, knownthermal-set based swirl rings, which are reused repeatedly with varioussets of electrodes and nozzles, commonly have lifecycles of 20 to 30times that of electrodes and nozzles. These lifecycles placerequirements and demands on the swirl rings, which can lead to overdesign and also inconsistent performance as the swirl rings canthermally warp (e.g., expand and/or shrink) over their lifecycles,providing different fits, interfaces, and performance based on lifecycleposition.

In some embodiments, the elongated body 103 of the swirl ring 102 isformed using an injection molding technique (e.g., thermoplasticinjection molding). In some embodiments, if the gas flow openings 136include slots 202 defined by the distal end 110 of the swirl ring 102,the slots 202 can be formed at the same time as the elongated body 103via the same thermoplastic injection molding process. In general, thegas flow slots 202, in contrast to drilled holes in accordance withtraditional designs for creating gas flow passageways, are morecompatible with the injection molding technique for forming the swirlring 102. Thus, molding the gas flow slots 202 into the swirl ring body103 eliminates the additional step of drilling holes into the body 103.Using gas flow slots 202 instead of drilled holes in a swirl ring designalso reduces material cost and the cost of long cycle time associatedwith drilling operations. The nozzle retention feature 216 and/or thecap retention feature 230 can also be formed at the same time as theelongated body 103 via the same thermoplastic injection molding process.Therefore, most, if not all, of the swirl ring 102 can be manufacturedusing a cost-effective single injection molding process. Overall, amolded thermoplastic process for forming the swirl ring 102 provides afaster and cheaper manufacturing approach in comparison to thetraditional processes. Processes and materials for manufacturing theswirl ring 102 of FIGS. 4 a and b can also be used to manufacture theswirl ring 702 of FIGS. 5 a and b.

FIGS. 7 a and b are isometric and sectional views of the end cap 106(e.g., a crown) of the cartridge 100 of FIG. 1 , respectively, accordingto an illustrative embodiment of the invention. The end cap 106 providesat least one of the following functions: (i) securely engaging the swirlring 102 or 702 at its proximal end 112 to form the interface 120,thereby aligning the electrode 104; (ii) providing a holder for theresilient element 122; and (iii) passing an electrical current to theelectrode 104 in a blow-back contact-start configuration. Asillustrated, the end cap 106 has a substantially hollow body 300defining a proximal end 320 and a distal end 322. The hollow body 300includes a circular tunnel portion 302 and a depressed center 304extending away from the proximal end 320 of the end cap 106. In someembodiments, the body 300 of the end cap 306 has a substantially uniformthickness, thereby promoting efficient and uniform current passage andassisting with the establishment of precise consumables alignment.Uniform thickness of the end cap 106, coupled with a stamp manufacturingtechnique, also simplifies manufacturing and minimizes manufacturingcycle time, consumable weight, and material usage.

In some embodiments, an interior surface 308 of the circular tunnelportion 302 at the proximal end 320 defines a biasing surface forphysically contacting and electrically communicating with the resilientelement 122. The resilient element 122 can bias against the proximal end124 of the electrode 104 so as to move the electrode 104 away from theend cap 106. That is, the resilient element 122 is situated between andphysically contacts the biasing surface 308 of the end cap 106 and theproximal end 124 of the electrode 104 such that the resilient element122 imparts a separation force between the electrode 104 and the biasingsurface 308.

In some embodiments, an interior surface 310 of the depressed center 304of the end cap 106 at the distal end 322 defines a contact surface thatis configured for physical contact and electrical communication with acorresponding contact surface 128 of the electrode 104 at its proximalend 124. During the transferred arc mode, the contact surface 310 of theend cap 106 is in an abutting relationship with the correspondingcontact surface 128 of the electrode 104. However, during the initiationof a pilot arc in the pilot arc mode, the contact surface 310 is in aspaced relationship with the corresponding contact surface 128 that isdefined by an absence of contact between the two surfaces.

The resilient element 122 is generally maintained inside of thecartridge 100 between the end cap 106 and the electrode 104. In someembodiments, the resilient element 122 is secured to either the end cap106 or the electrode 104. In other embodiments, the resilient element122 is secured to both the electrode 104 and the end cap 106. Forexample, the resilient element 122 can be secured by welding, soldering,bonding, fastening, a diametral interference fit or another type offriction fit to the end cap 106 and/or the electrode 104. In someembodiments, the substantially hollow body 300 of the end cap 106 isconfigured to house the resilient element 122 between its biasingsurface 308 and the proximal end 124 of the electrode 104. For example,the circular tunnel portion 302 of the end cap 106 can function as aholder of the resilient element 122. Specifically, the resilient element122 can be held in place by the biasing surface 308, an inner interiorsurface 312 and an outer interior surface 314 of the tunnel portion 302,where the diameter of the inner interior surface 312 with respect to thelongitudinal Axis A is slightly smaller than the inner diameter of theresilient element 122, and the the diameter of the outer interiorsurface 314 with respect to the longitudinal Axis A is slightly largerthan the outer diameter of the resilient element 122.

In some embodiments, radial movement of the resilient element 122 isfurther restrained by the proximal end 112 of the swirl ring 102 or 702after the swirl ring 102 or 702 is affixed to the end cap 106. As shownin FIG. 1 , after the end cap 106 is coupled to the swirl ring 102(e.g., by being crimped into the cap engagement groove 230), the lipportion 232 of the swirl ring 102 can extend into the interior of thecircular tunnel portion 302 of the end cap 106. Therefore, the lipportion 232 can further restrain and guide the positioning of theresilient element 122 inside of the end cap 106.

In some embodiments, the end cap 106 is configured to be in electricalcommunication with a power supply (not shown) when the cartridge 100 isinstalled within a torch. This enables a flow of current from the powersupply to the electrode 104 via the resilient element 122 and/or thecontact surface 310, depending on the mode of torch operation. In someembodiments, at least one vent hole 316 (or gas exit orifice) isdisposed in the end cap 106, extending from an interior surface to anexterior surface of the body 300 to cool the cartridge 100. For example,a vent hole 316 can be located on the circular portion 302.Alternatively, vent hole(s) 316 are absent from the end cap 106.

In one exemplary operation, during pilot arc initiation, the powersupply provides a pilot arc current to the end cap 106 and the pilot arccurrent is passed to the electrode 104 through the resilient element 122that biases the electrode 104 against nozzle 108. As the resilientelement 122 urges the electrode 104 into abutting relation with thenozzle 108, there is an absence of physical contact and electricalcommunication between the contact surface 310 of the end cap 106 and thecorresponding contact surface 128 of the electrode 104. The resilientelement 122 can be configured to pass substantially all of the pilot arccurrent from the end cap 106 to the electrode 104.

During pilot arc initiation, a gas is introduced into the plasma chamber140 between the electrode 104 and the nozzle 108. Gas pressure can buildwithin the plasma chamber 140 until the pressure is sufficient toovercome the separation force exerted by the resilient element 122. Atthat point, the gas pressure moves the electrode 104 toward the end cap106 and away from the nozzle 108 along the longitudinally axis A (whilecompressing the resilient element 122) until the corresponding contactsurface 128 of the electrode 104 comes into physical contact with thecontact surface 310 of the end cap 106. As the electrode 104 is movedaway from the nozzle 108 by gas pressure, an arc is generated orinitiated in the plasma chamber 140 to form a plasma arc or jet that canbe transferred to a workpiece (not shown).

During transferred arc mode, the corresponding contact surface 128 ofthe electrode 104 engages in substantially planar physical contact withthe contact surface 310 of the end cap 106 to establish electricalcommunication (e.g., electrical current passes between the end cap 106and the electrode 104 at the interface of the contact surface 310 andthe corresponding surface 128). When the contact surface 310 of the endcap 106 abuts the corresponding surface 128 of the electrode 104, acurrent path is established such that at least a portion of a currentpasses directly between the two components. When the arc has beentransferred to the workpiece, a cutting current is supplied to the torch(e.g., during transferred arc mode). The cutting current can be passedfrom the end cap 106 to the electrode 104 during transferred arcoperation via (1) the resilient element 122 and/or (2) the interfacebetween the contact surfaces 310, 128. In some embodiments, the currentpath directly between the end cap 106 and the electrode 104 has lowerresistance and/or higher conductance than the current path from the endcap 106 through the resilient element 122 to the electrode 104. Hence,substantially all of the electrical current for sustaining a plasma arc(in transferred arc mode) can be passed directly between the contactsurfaces 128, 310.

In some embodiments, the resilient element 122 is formed from a materialthat facilitates both carrying an electrical current and dissipatingthermal heat associated with the current to prevent the resilientelement 122 from melting. For example, the material of the resilientelement 122 can be selected based on the current rating of the material.In some embodiments, the resilient element 122 comprises a helicalcompression spring, wire, or metal strip. For example, different typesof resilient element 122 configurations are described in U.S. Ser. No.13/344,860, assigned to Hypertherm, Inc., of Hanover, N.H., the contentsof which are hereby incorporated herein by reference in their entirety.

In some embodiments, the end cap 106 is fabricated from an electricallyconductive material, such as copper, copper alloy, brass, or othermaterials suitable for passing current both during pilot arc operationand transferred arc operation. The end cap 106 can be formed using astamping approach from a material blank.

In another aspect, the cartridge 100 can additional include a shield.FIG. 8 shows an exemplary shield 600 compatible with the cartridge 100of FIG. 1 , according to an illustrative embodiment of the invention.The shield 600 can be made from a conductive material, such as copper orsilver. The shield 600 can be affixed to the nozzle 108 via one ofcrimping, threading and snap-fit. In some embodiments, a flow passageway(not shown) is disposed in the nozzle 108 to allow a gas (e.g., a shieldgas) to flow through/by the nozzle 108 to the shield 600.

FIG. 9 is an exploded view of the cartridge 100 of FIG. 1 , according toan illustrative embodiment of the invention. FIG. 9 shows the nozzle108, the electrode 104, the swirl ring 102, the resilient element 122,the sealing device 150, and the end cap 106 in an unassembled statebefore forming the cartridge 100. In some embodiments, the insert 142 isalso a part of the cartridge 100. During assembly, the electrode 104 ishoused in the chamber formed by the coupling of the nozzle 108 to thedistal end 110 of the swirl ring 102. The nozzle 108 can be securelyaffixed to the outer wall of the swirl ring 102 through the retentionelement 216 (e.g., a groove disposed on the swirl ring 102 against whichthe nozzle 108 is crimped or a thread to which the nozzle 108 isthreaded). This interconnection secures the electrode 104 within thecartridge 100 while the inner wall of the swirl ring axially aligns theelectrode 104 about the longitudinal axis A with respect to the nozzle108 such that the electrode 104 is limited in its axial motion. Theresilient element 122 is inserted into the swirl ring 102 from itsproximal end 112 until it contacts the proximal end 124 of the electrode104 within the swirl ring 102. The end cap 106 is then securely affixedto the proximal end 112 of the swirl ring 102 while substantiallyconfining the resilient element 122 in the circular portion 304 of theend cap 106 and axially aligning the resilient element relative to theend cap 106. The end cap 106 can be connected to the swirl ring 102through the retention element 230 (e.g., a groove disposed on the swirlring 102 against which the end cap 106 is crimped or a thread to whichthe end cap 106 is threaded). This interconnection enables the biasingsurface 308 of the end cap 106 to bias the resilient element 122 againstthe proximal end of the electrode 104, thereby urging it into anabutting position with the nozzle 108. This interconnection alsolongitudinally aligns the electrode 104 with respect to the end cap 106such that during the transferred arc mode, the electrode 104 is onlyable to retract from the nozzle 108 far enough until it abuts thecontact surface 310 of the depressed portion 304 of the end cap 106.Furthermore, the sealing device 150 can be disposed around an exteriorsurface of the proximal end 112 of the swirl ring 102 either before orafter the end cap 106 is affixed to the swirl ring 102. In someembodiments, the swirl ring 702 of FIGS. 5 a and b are used in thecartridge 100 in place of the swirl ring 102.

In some embodiments, a method is provided to assemble the cartridge 100of FIG. 1 . First, a thermoplastic material is molded to form the swirlring 102 or 702. Various features of the swirl ring 102 or 702 can becreated during the same molding process, such as the gas flow openings136 and/or the nozzle retention surface 216 molded at the distal end 110of the swirl ring 102. Similar features can be molded onto the swirlring 702. During assembly, the electrode 104 can be disposed inside ofthe hollow body of the swirl ring 102 or 702. The inside wall of theswirl ring 102 or 702 can radially align the electrode 104. Theelectrode can be retained within the swirl ring 102 or 702 by fixedlysecuring the nozzle 108 to the distal end 110 of the swirl ring 102 or702 via the nozzle retention surface 216 or 716, respectively. Forexample, the fixedly securing can be achieved through one of crimping,threading or snap-fitting with respect to the nozzle retention surface216 or 716. Upon affixing the nozzle 108 to the swirl ring 102 or 702, aradial centering of the nozzle exit orifice 144 with respect to thedistal end 125 of the electrode 104 is established. The electrode 104can be longitudinally aligned relative to the nozzle 108 by fixedlysecuring an end cap 106 to the proximal end 112 of the swirl ring 102 or702 via the cap retention element 230 or 730, respectively, therebyestablishing the longitudinal alignment during a transferred arcoperation of the cartridge 100 when a gas flow is used to bias theelectrode 104 into contact with the end cap 106. Specifically, duringthe transferred arc mode, the longitudinal alignment includesrestraining a longitudinal motion of the electrode 104 to within ablow-back distance defined by the distal end 125 of the electrode 104and the exit orifice 144 of the nozzle 108. In some embodiments, theresilient element 122 is inserted into the end cap 106 and housed in thetunnel portion 302 of the end cap 106 prior to affixing the end cap tothe swirl ring 102 or 702. In some embodiments, the sealing device 150,such as in the form of an o-ring, can be located on an external surfaceof the swirl ring 102 or 702 at its proximal end 112 to engage aninternal surface of the plasma arc torch body (not shown) when the thecartridge 100 is installed into the plasma arc torch body.

Test results have shown that the cartridge design 100 of FIG. 1 ,operating at a current of 105 amps, can have the same or betterperformance than that of individual consumables (e.g., a nozzle,electrode, and swirl ring) assembled into a PMX 105 Amp plasma arc torch(operated at 105 amps), and at a lower manufacturing cost. Table 1 showsa comparison of performance and cost between the cartridge 100 and theindividual consumables for a PMX 105 Amp plasma arc torch.

Cartridge 100 PMX 105 Amp Torch Anode life at 105A (hours) 2.5 2.2 Maxcut speed at ½” mild 95 95 steel (in per minute)

The cost of the cartridge 100, which represents the combined cost of aswirl ring, electrode and nozzle (i.e., without an end cap), is lowerthan the total cost of the individual consumables in a PMX 105 Amptorch, which includes the cost of just a nozzle and an electrode (i.e.,when a swirl ring is not even considered). In term of performance, atorch having the cartridge 100 installed therein has comparable maximumcut speed as compared to a PMX 105 Amp torch that contains individualconsumable components. Performance of a torch containing the cartridge100 is also better in terms of anode life.

In addition to the benefits described above, there are many othersbenefits associated with using the cartridge 100 in a plasma arc torch.First, such a design promotes ease of use through quick changecapabilities, short setup time and ease of consumable selection for anend user. It also provides consistent cut performance because a suite ofconsumables are changed at once when the cartridge is changed, where thecartridge promotes easy component alignment, thus accuracy andrepeatability of torch operation. In contrast, variation in performanceis introduced when components are changed individually at differenttimes. For example, there is more room to make an error when an operatorhas to align and orient individual torch components relative to eachother. In another example, long term re-use of the same component (e.g.,a swirl ring) can cause dimensional alteration after each blow-out,thereby altering the performance quality even if all other componentsare changed regularly. In addition, since the manufacturing and/orinstallation cost of a cartridge is lower than the combined cost of aset of consumables, there is a lower cost associated with per cartridgechange than per change of a set of consumables. Furthermore, differentcartridges can be designed to optimize torch operation with respect todifferent applications, such as marking, cutting, maintaining long life,etc.

In some embodiments, the cartridge 100 is single use, meaning thatdisassembly and replacement of individual components at the end of thelife of the cartridge is not practical or cost effective. The entirecartridge 100 is discarded and/or disposed (e.g., recycled), withoutreplacing individual particular parts. If the cartridge 100 is recycled,in addition to recovering the copper, a benefit of constructing theswirl ring 102 of a thermoplastic material is that the material can bereheated, reshaped, and frozen repeatedly, thus making it easilyrecyclable. In contrast, Vespel™ and other thermal-set materials lackthese characteristics that promote recyclability.

FIG. 10 is a sectional view of another exemplary consumable cartridgefor a contact start plasma arc torch, according to an illustrativeembodiment of the invention. As shown, the consumable cartridge 1000 hasan inner component 1004 and an outer component 1002. The outer component1002 can include at least one of a shield 1012, a retaining cap 1014, acap sleeve 1016 or an insulator component 1028. In some embodiments, theouter component 1002 comprises two or more of these components fixedlysecured to one another. The inner component 1004 can include at leastone of a crown 1006, a swirl ring 1007, an electrode 1008, or a nozzle1010. For example, the inner component 1004 can comprise all thesecomponents, as illustrated by the irregular box of FIG. 10 . The innercomponent 1004 can additionally include a resilient element 1026, whichcan be substantially the same as the resilient element 122 of FIG. 1 , asealing device 1030 and/or a signal device 2106. The electrode 1008 ofthe cartridge 1000 can be substantially the same as the electrode 104 ofFIG. 1 . For example, the electrode 1008 can include an emissive insert1042 (e.g., same as the insert 142).

Generally, the cartridge 1000 can include multiple consumable piecesthat are assembled together as an integrated, unitary device. In someembodiments, if any one of the elements in the cartridge 1000 needsreplacement, the entire cartridge 1000 is replaced. The cartridge 1000can use a blow-back contact starting mechanism for contact starting aplasma arc torch upon assembly into the torch. For example, theelectrode 1008 can be a spring-forward electrode, which means that theresilient element 1026 (e.g., a spring) can exert a separating force onthe proximal end of the electrode 1008 to bias the electrode 1008 awayfrom the crown 1006 and toward the nozzle 1010.

The outer component 1002 includes a substantially hollow body thatdefines a longitudinal axis A, a distal end 1017 (i.e., the end closestto a workpiece during operation of a plasm arc torch incorporating thecartridge 1000), and a proximal end 1018 (i.e., the end opposite of thedistal end 1017). The inner component 1004 is adapted to be disposedsubstantially within the hollow body of the outer component 1002 with atleast a portion of the inner component 1004 surrounded by the hollowbody. The inner component 1004 can include an engagement featuredisposed on an inner or outer surface to engage the outer component 1002by longitudinally constraining (i.e., axially securing) the outercomponent 1002 relative to the inner component 1004 while permittingindependent rotation of the components relative to each other (i.e.,enabling rotatable engagement) when the cartridge 1000 is not assembledin a plasma arc torch. Such rotatable engagement and axial securementcan be accomplished by one of crimping, snap fitting, frictional fittingor threading.

The inner component 1004 can include the nozzle 1010, the swirl ring1007, the electrode 1008 and the crown 1006. In some embodiments, therotatable engagement and axial securement between the outer and innercomponents occurs between the nozzle 1010 of the inner component 1004and the retaining cap 1014 of the outer component 1002 at the interface1020 by one of a frictional fit, crimping, snap fit or threadingconnection. For example, the nozzle 1010 can include an engagementfeature, such as a groove, circumferentially disposed on an externalsurface that allows a distal tip of the retaining cap 1014 tofrictionally fit into the groove. In some embodiments, the nozzle 1010is fixedly secured to (i.e., axially and radially restrains) theretaining cap 1014 at the interface 1020. In this case, the rotatableengagement and axial securement between the outer and inner componentscan be indirectly accomplished by rotatable engagement and axialsecurement between the swirl ring 1007 and the nozzle 1010 of the innercomponent 1004 at the interface 1021, where the nozzle 1010 is fixedlysecured to the outer component 1002. In some embodiments, the nozzle1010 is fixedly secured to the retaining cap 1014 at the interface 1020,and the swirl ring 1007 is fixedly secured to the nozzle 1010 at theinterface 1021. In this case, the rotatable engagement and axialsecurement between the outer and inner components can be indirectlyaccomplished by rotatable engagement and axial securement between thecrown 1006 and the swirl ring 1007 of the inner component 1004 at theinterface 1023, where the swirl ring 1007 is fixedly secured to theouter component 1002 via its connection to the nozzle 1010.

Generally, the inner component 1004 can be divided into a forwardportion and a rear portion with respect to the location of the rotatableengagement and axial securement feature. For example, the forwardportion includes the rotatable engagement and axial securement featurewhile the rear portion does not. That is, the rear portion can have nomeans for enabling axial securement and rotatable engagement with theouter component 1004. As an example, if the rotatable engagement andaxial securement feature is disposed on the nozzle 1010, the forwardportion of the inner component 1004 includes the nozzle 1010 and therear portion includes the electrode 1008, swirl ring 1007 and/or crown1006. As another example, if the rotatable engagement and axialsecurement feature is between the swirl ring 1007 and the nozzle 1010,the forward portion of the inner component 1004 includes the swirl ring1007 and the nozzle 1010, while the rear portion includes the electrode1008 and the crown 1006. Upon rotatable engagement and axial securementof the inner and outer components at the forward portion of the innercomponent 1004, the rear portion of the inner component 1004 is adaptedto be substantially suspended within the hollow body of the outercomponent 1002. Thus, via the rotatable engagement and axial securementof the inner and outer components at the forward portion, the rearportion can have little to no direct physical contact with the innersurface of the hollow body of the outer component 1002 while remainingsubstantially radially centered within the hollow body of the outercomponent 1002.

In some embodiments, the cartridge 1000 includes a hollow region 1022between the rear portion of the inner component 1004 and the proximalend 1018 of the outer component 1004. As shown, the hollow region 1022can include (i) a center cavity portion 1022 a in the recess of thecrown 1006 and (ii) a tubular portion 1022 b between the outer surfaceof the crown 1006 and swirl ring 1007 and the inner surface of theretaining cap 1014 and cap sleeve 1016. The tubular portion 1022 b cansubstantially surround the center cavity portion 1022 a and extendfurther into the cartridge 1000 than the center cavity portion 1022 a.The hollow region 1022 is configured to receive a torch head (not shown)to enable mating between the rear portion of the inner component 1004(e.g., the crown 1006) and certain components of the torch head (e.g., acathode), as described below in detail with reference to FIGS. 21 and 22.

As described above, the outer component 1002 can include at least one ofthe shield 1012, retaining cap 1014 or cap sleeve 1016 orientedsubstantially symmetrically about the longitudinal axis A. In someembodiments, the outer component 1002 also includes an insulatorcomponent 1028. The retaining cap 1014 and/or the shield 1012 can beconstructed from an electrically and/or thermally conductive material,such as copper or brass. The two components can be made of the samematerial or different materials (e.g., the shield 1012 can be made ofcopper and the retaining cap 1014 can be made of brass). The cap sleeve1016 and/or the insulator component 1028 can be manufactured throughinjection molding of a plastic material (e.g., nylon resin) or ahigh-temperature thermoplastic material comprising a polymer formed ofether and ketone molecules (e.g., ether ketone based compounds), such aspolyetheretherketone (PEEK). In some embodiments, at least one of thecap sleeve 1016 or insulator component 1028 is manufactured from thesame or similar material as the swirl ring 102 or 702. In someembodiments, the insulator component 1028 is manufactured from anelectrically insulating material (e.g., plastic) that can withstand ahigher temperature than that of the cap sleeve 1016. Generally, each ofthe interfaces among various elements of the outer component 1002 can beformed by one of crimping, snap fit, frictional fit, or threading.

FIG. 11 is an exemplary configuration of the retaining cap 1014 of thecartridge 1000 of FIG. 10 . The retaining cap 1014 can have asubstantially hollow body with a substantially uniform thickness.Uniform thickness of the retaining cap 1014, coupled with a stamptechnique for manufactures the component, simplifies manufacturingprocedure and minimizes manufacturing cycle time, consumable weight, andmaterial usage. Generally, the retaining cap 1014 can include threesubstantially hollow, cylindrical portions—a distal portion 1106, amiddle portion 1107, and a proximal portion 1108. The portions can stacktogether along the longitudinal axis A and form a stepped configurationwhere the distal portion 1106 can have a smaller diameter in the radialdirection (i.e., perpendicular to the axis A) than that of the middleportion 1107, which can have a smaller diameter than that of theproximal portion 1108.

In some embodiments, an interior surface the distal portion 1106 of theretaining cap 1014 includes a retention feature 1102 (e.g., aprotrusion, tab or flange) configured to rotatably engage and axiallysecure to the forward portion of the inner component 1004 (e.g. at thenozzle 1010 of the inner component 1004) via one of snap fit, frictionalfit, crimping or threading, when the forward portion is disposed in thehollow body of the retaining cap 1014. As shown, the retention feature1102 comprises a protrusion 1102 a, which can be generated by bending aportion of the wall of the retaining cap 1014. The protrusion 1102 a isadapted to snap fit into a groove on the nozzle 1010. In addition, theretention feature 1102 includes a bumper 1102 b adjacent to theprotrusion 1102 a to generate friction between the retaining cap 1014and the nozzle 1010 upon engagement via frictional fit. The protrusion1102 a and the bumper 1102 b are dimensioned as such that they permitthe components to independently rotate relative to each other afterengagement. Alternatively, the retention feature 1102 can be suitablyconfigured to fixedly engage (i.e., axially and radially secure) theforward portion of the inner component 1004. In some embodiments, asection of the retaining cap 1014, such as the distal portion 1106 ofthe retaining cap 1014, includes at least one vent hole 1112 extendingfrom an interior surface to an exterior surface of the retaining cap1014 to permit a flow of gas therethrough.

In some embodiments, the proximal portion 1108 of the retaining cap 1014includes one or more threads 1104 to engage a torch head (not shown) ofa plasma arc torch when the cartridge 1000 is installed into the torch.In some embodiments, two or more discrete threads 1104 (e.g., threethreads) can be disposed circumferentially around an interior surface ofthe proximal portion 1108 of the retaining cap 1014 to engage a setcomplementary threads on the torch head, when at least a portion of thetorch head is disposed in the hollow body of the proximal portion 1108.Locking between the torch head and the retaining cap 1014 requiresrotation of one component relative to the other by a degree depending onthe number of discrete threads 1104 disposed on the retaining cap 1014.For example, if there are three discrete threads 1104, a rotation ofonly about 120 degrees is needed to lock the components to each other.This facilitates quick installation of the cartridge 1000 onto a plasmaarc torch. In general, the retaining cap 1014 has sufficient materialthickness and/or strength to retain the cartridge 1000 to the torch headvia the threaded engagement.

FIGS. 12 a and 12 b are sectional and exterior profile views,respectively, of an exemplary cap sleeve 1016 overmolded onto themetallic retaining cap 1014 of FIG. 11 , which can form at least aportion of the outer component 1002. As shown in FIG. 12 a , the capsleeve 1016 has a substantially hollow body, at least a portion of whichis overmolded onto the external surfaces of the middle and proximalportions 1107, 1108 of the retaining cap 1014. In some embodiments, onlythe distal portion 1106 of the retaining cap 1014 is fully exposed. Thecap sleeve 1016 can include a proximal end 1206 and a distal end 1208along the longitudinal axis A. In some embodiments, the distal end 1208of the cap sleeve 1016 includes one or more retention features forengaging the insulator component 1028. For example, the distal end 1208of the cap sleeve 1016 can be molded over the middle portion 1107 of theretaining cap 1014 as one or more tabs 1209. A raised feature 1210 canbe disposed on each the tabs 1209. The combination of the tabs 1209 andthe raised features 1210 can be used to engage the insulator component1028, as explained below in detail with reference to FIGS. 14 a-c . Insome embodiments, the cap sleeve 1016 includes one or more retentionfeatures for engaging the shield 1012. For example, the cap sleeve 1016can include at least one groove 1212 disposed on an external surface,against which a portion of the shield 1012 can be crimped to secure thetwo components together.

As shown in FIG. 12 b , the cap sleeve 1016 substantially surrounds theretaining cap 1014 at its middle and proximal portions 1107, 1108 andcan extend proximally beyond the retaining cap 1014 in the longitudinaldirection. In some embodiments, the interior diameter 1202 of the capsleeve 1016 near where the cap sleeve 1016 overlaps with the proximalportion 1108 of the retaining cap 1014 is smaller than the interiordiameter 1204 of the cap sleeve 1016 at the proximal end 1206 of the capsleeve 1016, such as by a draft of 0.5 degrees. This varying innerdiameter along the length of the cap sleeve 1016 helps to guideinsertion of the torch head (not shown) into the retaining cap 1014 andfacilitates their relative alignment prior to rotation of one componentrelative to the other to achieve engagement at the discrete threads 1104of the retaining cap 1014.

FIG. 13 is an exemplary configuration of the insulator component 1028,which can be a part of the outer component 1002 of the cartridge 1000 ofFIG. 10 or a stand-alone element. The insulator component 1028 isgenerally circular in shape and constructed from an electricallynon-conductive material. The insulator component 1028 can be locatedbetween the shield 1012 and the retaining cap 1014/cap sleeve 1016combination of the outer component 1002 to space the majority of theouter component 1002 (e.g., the retaining cap 1014 and the cap sleeve1016) from the shield 1012 and to electrically insulate the retainingcap 1014 from the shield 1012. The insulator component 1028 includes ashoulder 1304, also referred to as a contour, step, or flange, locatedat the distal end 1301 of the insulator component 1028. The shoulder1304 is oriented substantially perpendicularly to the longitudinal axisA. The shoulder 1304 defines an opening 1316 that complements the shapeof the distal portion 1106 of the retaining cap 1014 and permits thedistal portion 1106 therethrough. In some embodiments, the opening 1316has a diameter that is substantially the same as or larger than thediameter of the distal portion 1106 of the retaining cap 1014, butsmaller than the diameter of the middle portion 1107 of the retainingcap 1014, such that the middle portion 1107 cannot pass through theopening 1316. An external surface of the shoulder 1304 can include oneor more channels 1318 dispersed about the opening 1316 to provide a gasflow path such that a portion of a gas flowing to the shield 1012 cantravel through the channels 1318 to cool the insulator component 1028and the shield 1012.

The insulator component 1028 also includes a substantially hollowcylindrical body 1302 located at the proximal end 1303 of the insulatorcomponent 1028. The cylindrical body 1302 is disposed about thelongitudinal axis A and extends along the longitudinal axis. In someembodiments, retention features are provided on the cylindrical body1302 to engage the insulator component 1028 with the shield 1012 and/orthe cap sleeve 1016. For example, a cap sleeve retention feature 1305can include a slot 1306 extending from an interior surface to anexterior surface of the cylindrical body 1302. The slots 1306 aredefined by a plurality of extensions 1308 disposed about the cylindricalbody 1302, where each slot 1306 is situated between a pair of theextensions 1308. The cap sleeve retention feature 1305 can also includeat least one groove 1310 on an internal surface of the cylindrical body1302 centered around a corresponding slot 1306 and on the extensions1308. The grooves 1310 and the slots 1306, which made up the cap sleeveretention features 1305, are configured to cooperatively engage the capsleeve 1016 by one of frictional fit, snap fit, threading or crimping. Ashield retention feature 1311 can include at least one groove disposedon an external surface of the cylindrical body 1302, such as adjacent toa slot 1306. The grooves 1311 are configured to engage the shield 1012via crimping, for example.

FIGS. 14 a-c are various views of the insulator component 1028 of FIG.13 fixedly secured to the cap sleeve 1016 and the retaining cap 1014.The three components 1028, 1016, 1014 can form at least a portion of theouter component 1002. During assembly, the distal portion 1106 of theretaining cap 1014 can slide through the opening 1316 defined by theshoulder 1304 of the insulator component 1028 until an interior surface1320 of the shoulder 1304 abuts against an exterior surface 1110 of themiddle portion 1107 of the retaining cap 1014 and no further advancementis possible. At this point, the combination of the retaining cap 1014and the cap sleeve 1016 are securely seated against the insulatorcomponent 1028, with the insulator component 1028 substantiallysurrounding the exterior surface 1110 of the middle portion 1107 of theretaining cap 1014. The grooves 1310 and the slots 1306 of the capsleeve retention feature 1305 of the insulator component 1028 can engagethe retention feature 1210 of the cap sleeve 1016 via frictional fit,for example, to connect the insulator component 1028 to the cap sleeve1016. The friction for the frictional fit can be supplied by thecrimping force of the shield 1012 when it is attached to the insulatorcomponent 1028. Specifically, the grooves 1311 of the insulatorcomponent 1028 can provide a surface to which the shield 1012 is crimpedagainst to fixedly connect the insulator component 1028 to the shield1012. In addition, the connection between the insulator component 1028and the cap sleeve 1016 also fixedly engages the insulator component1028 to the retaining cap 104 via its fixed connection to the cap sleeve1016 (i.e., the cap sleeve 1014 is overmolded onto the middle portion1107 of the retaining cap 1014).

FIG. 14 c illustrates a cross-sectional view of the assembly comprisingthe insulator component 1028, the cap sleeve 1016 and the retaining cap1014, where the cross-sectional view is in the radial plane and from theperspective of a viewer at the distal end of the assembly. As shown,upon abutment of the insulator component 1028 against the retaining cap1014, the one or more grooves 1310 in the interior surface of theinsulator component 1028 can snap fit with the tabs 1209 of the capsleeve 1014, while the raised regions 1210 of the cap sleeve 1014 can beinserted into the slots 1306 of the insulator component 1028. Such snapfit connection can fixedly join the insulator component 1028 with thecap sleeve 1016 (and also to the retain cap 1014 through the overmoldedcap sleeve 1016). Because the cross-sectional dimension of each raisedregion 1210 is less than that of each slot 1306, each raised region 1210is adapted to leave at least a portion of each slot 1306 unobstructed,thus permitting gas flow therethrough. As shown in FIG. 14 c , the capsleeve 1016 and the insulator component 1028 can engage at fourlocations radially disposed around the longitudinal axis A. In otherembodiments, fewer or more engagement locations are constructed.

FIG. 15 is an exemplary configuration of the shield 1012, which can be apart of the outer component 1002 of the cartridge 1000 of FIG. 10 or astand-alone piece. The shield 1012 of FIG. 15 can be used in ahand-cutting plasma arc torch. The shield 1012 comprises a substantiallyhollow body. A section in a proximal portion 1502 of the hollow body canbe crimped against one or more grooves 1212 on the distal end 1208 ofthe cap sleeve 1014 to securely connect the shield 1012 to the capsleeve 1016. Another section of the proximal portion 1502 can be crimpedagainst the grooves 1311 of the insulator component 1028 to securelyconnect the shield 1012 to the insulator component 1028. Theseconnections also fixedly engage the shield 1012 to the retaining cap1014 via their common connection (either directly or indirectly) to thecap sleeve 1016. Other means for connecting the shield 1012 to the capsleeve 1016 and/or the insulator component 1028 are also within thescope of the present invention, including threading or snap fit. Theshield 1012 can also include a shield exit orifice 1506 and one or moregas vent holes 1504 disposed on a body of the shield 1012 extending froman interior surface to an exterior surface of the shield 1012.

FIG. 16 is another exemplary shield 1600 that is compatible with thecartridge 1000 of FIG. 10 . The shield 1600 can be used in a mechanizedplasma arc torch. The shield 1600 can also include a proximal portion1602 that is substantially the same as the proximal portion 1502 of theshield 1012 of FIG. 15 to securely connect the shield 1600 to the capsleeve 1016 and the insulator component 1028 by one of crimping,frictional/snap fit or threading. The shield 1600 can also include ashield exit orifice 1606 and one or more gas vent holes 1604, similar tothe shield 1012 of FIG. 15 .

In other embodiments, the shield 1012 can be substantially the same asthe shield 800 described above with respect to FIG. 8 . In someembodiments, the insulator component 1028 is dimensioned to align andcenter the shield 1012 relative to the retaining cap 1014 and the capsleeve 1016 in the radial direction. As clearly illustrated in FIG. 10 ,the insulator component 1028 spaces the shield 1012 from the combinationof retaining cap 1014 and cap sleeve 1016. Thus, when the shield 1012 isfixedly connected to the cap sleeve 1016 and/or the insulator component1028, the tight tolerance among the components minimizes radial movementof the shield 1012 that can result in its radial misalignment.

As described above with reference to FIG. 10 , the inner component 1002can include at least one of the crown 1006, electrode 1008, swirl ring1007 or nozzle 1010 oriented substantially symmetrically about thelongitudinal axis A. The inner component 1002 can additionally includethe resilient element 1026, the sealing device 1030 and/or the signaldevice 2106. Generally, each of the interfaces among various elements ofthe inner component 1004 can be formed by one of crimping, snap fit,frictional fit, or threading to fixedly connect (i.e., axially andradially secure) or axially secure and rotatably engage the components.In some embodiments, the inner component 1004 is substantially the sameor similar to the cartridge 100 described above with reference to FIG. 1. For example, the electrode 1008 can be substantially the same as theelectrode 104 of FIG. 2 . The electrode 1008 can be relatively flat nearthe proximal end such that the electrode 1008 provides a stable surfacefor contacting the resilient element 1026.

The nozzle 1010 can be a part of the inner component 1004 of thecartridge 1000 in FIG. 10 . The nozzle 1010 can define, in relation tothe electrode 1008, a plasma chamber 1040. In some embodiments, thenozzle 1010 is substantially the same as the nozzle 108 of FIG. 3 . FIG.17 shows another exemplary configuration of the nozzle 1010 of thecartridge 1000 of FIG. 10 . The nozzle 1010 defines a distal portion1704, a middle portion 1705, and a proximal portion 1706 along thelongitudinal axis A. The nozzle 1010 can include a retention feature atthe proximal portion 1706, such as an indent 1702 with an inner surface1702 a and an outer surface 1702 b, configured to connect the nozzle1010 to the distal end of the swirl ring 1007 at the interface 1021 (asshown in FIG. 10 ). For example, the distal end of the swirl ring 1007can be inserted into the indent 1702, and at least one of the innersurface 1702 a or the outer surface 1702 b of the indent 1702 can becrimped against a groove on the distal end of the swirl ring 1007 tosecure the two components together. Connection between the nozzle 1010and the swirl ring 1007 at the interface 1021 can be one of (i)rotatable engagement and axial securing or (ii) fixed engagement (i.e.,axial and radial securing) via one of snap fit, crimping, frictional fitor threading. As will be described below, the engagement between thenozzle 1010 and the swirl ring 1007 is adapted to control the swirlstrength of a gas at the interface 1021 as the engagement defines thesize and shape of the swirl holes of the swirl ring 1007 upon assembly.

The nozzle 1010 can also include a retention feature in the middleportion 1705, such as one or more grooves 1708 circumferentiallydisposed on an outer surface of the nozzle 1010, to rotatably engage andaxially secure the retention feature 1102 of the retaining cap 1014 toform the interface 1020 (as shown in FIG. 10 ) via one of snap fit,frictional fit, crimping or threading. Alternatively, the retentionfeature 1708 can be configured to fixedly secure (i.e., axial and radialsecure) the retaining cap 1014 thereto to form the interface 1020. Uponengagement, the retaining cap 1014 substantially surrounds the outersurface of at least the middle portion 1705 and the proximal portion1706 of the nozzle 1010. The nozzle 1010 can further include a series offlat elements 1710 a interspersed among a series of raised elements 1710b circumferentially disposed on an external surface of the middleportion 1705. The raised elements 1710 b facilitates radial alignmentand centering of the nozzle 1010 relative to the retaining cap 1014 andthe flat elements 1710 a provide spacing between the nozzle 1010 and theretaining cap 1014 to permit gas flow therethrough.

FIG. 18 is cross-sectional view of an assembly comprising the nozzle1010, the retaining cap 1014 and the shield 1012, where thecross-sectional view is in the radial plane and from the perspective ofa viewer at the proximal end of the assembly. The assembly also includesthe electrode 1008. As shown, these components can be radially alignedand concentrically positioned with a common center 1802. At least aportion of the electrode 1008 is disposed within a cavity defined by theinner wall of the nozzle 1010 that can radially align the electrode 1008by limiting a radial movement of the electrode 1008. At least a portionof the nozzle 1010 can be disposed within a cavity defined by the innerwall of the retaining cap 1014 that radially aligns the nozzle 1010 bylimiting a radial movement of the nozzle 1010. Specifically, the raisedelements 1710 b on the external surface of the nozzle 1010 areconfigured to abut against the correspond inner surface of the retainingcap 1014 to radially orient the nozzle 1010 relative to the retainingcap 1014. The flat elements 1710 a on the external surface of the nozzle1010 allow spacing between the nozzle 1010 and the retaining cap 1014such that a gas can flow therethrough. At least a portion of theretaining cap 1014 is disposed within a cavity defined by the inner wallof the shield 1012 that can radially align the retaining cap 1014 bylimiting a radial movement of the retaining cap 1014.

As described above, the swirl ring 1007 can be a part of the innercomponent 1004 of the cartridge 1000 in FIG. 10 . In some embodiments,the swirl ring 1007 is substantially the same as the swirl ring 102 ofFIGS. 4 a and 4 b . In some embodiments, the swirl ring 1007 issubstantially the same as the swirl ring 702 of FIGS. 5 a and 4 b .FIGS. 19 a-c are various views of another exemplary configuration of theswirl ring 1007 of the cartridge 1000 of FIG. 10 . The swirl ring 1002can be made of the same material and/or from the same manufacturingprocess as the swirl 102 or 702. As shown, the swirl ring 1002 can bedefined by a substantially hollow, elongated body having a distal end1910 and the proximal end 1912 along the longitudinal axis A. The hollowbody of the swirl ring 1007 is dimensioned to receive the electrode 1008and substantially extend over the length of the electrode 1008 along thelongitudinal axis A. The inner wall of the swirl ring 1007 can thusradially align the electrode 1008 by limiting a radial movement of theelectrode 1008. In some embodiments, the fins of the electrode 1008 arewider than the opening of swirl ring 1007 at the proximal end 1912 suchthat the electrode 1008 is hindered from exiting the swirl ring 1007from the proximal end 1912.

The interface 1021 can be formed between the distal end 1910 of theswirl ring 1007 and the nozzle 1008 to join the two consumablecomponents together. The joining can fixedly secure (i.e., axially andradially secure) the swirl ring 1007 to the nozzle 1008 via one of snapfit, crimping, frictional fitting or threading. Alternatively, thejoining can rotatably engage and axially secure the swirl ring 1007 tothe nozzle 1008 (e.g., via one of snap fit, crimping, or frictionalfitting) that permits the components to independently rotate relative toeach other after engagement. For example, the swirl ring 1007 caninclude a nozzle retention surface 1930 (e.g., interior and/or exteriorsurface) of the swirl ring 1007 for fixedly securing or rotatablyengaging and axially securing the nozzle 1010 at its distal end 1910.The nozzle retention surface 1930 can be a feature (e.g., one or moregrooves) located on the external surface of the swirl ring 1007 (e.g.,on the extensions 1904) to capture the nozzle 1010 through crimping.Alternatively, a similar retention surface can be disposed on the nozzle1010 to retain the swirl ring 1007 thereto.

Another interface 1023 can be formed between the proximal end 1912 ofthe swirl ring 1007 and the crown 1006 to join the two consumablecomponents together. The joining can fixedly secure the crown 1006 andthe the swirl ring 1007 via one of snap fit, crimping, frictionalfitting or threading. Alternatively, the joining can rotatably engageand axially secure the swirl ring 1007 to the crown 1006 (e.g., via oneof snap fit, crimping, or frictional fitting) that permits thecomponents to independently rotate relative to each other afterengagement. For example, the swirl ring 1007 can include a retentionfeature 1932 located on a surface (e.g., interior and/or exteriorsurface) of the swirl ring 1007 for fixedly securing or rotatably engageand axially securing the crown 1006 at its proximal end 1912. Theretention feature 1932 can be one or more grooves located around anexternal surface of the swirl ring 1007 to capture the crown 1006through crimping, for example, to form the interface 1023.Alternatively, a similar retention feature can be disposed about crown1006 to join the swirl ring 1007 thereto. In general, the interface 1021and/or the interface 1023 form a chamber in which the electrode 1008 isdisposed and aligned (longitudinally and radially) relative to thenozzle 1010 and the crown 1006.

In some embodiments, the swirl ring 1007 has a set of radially spacedgas flow openings 1902 configured to impart a tangential velocitycomponent to a gas flow for the plasma arc torch, causing the gas flowto swirl. This swirl creates a vortex that constricts the arc andstabilizes the position of the arc on the insert 1042. The one or moregas flow openings 1902 are disposed about the distal end 1910 of itselongated body, such as around a circumference of its distal end 1910.In some embodiments, the one or more gas flow openings 1902 are molded.Each gas flow opening 1902 can extend from an interior surface to anexterior surface of the elongated body and is oriented to impart aswirling motion relative to the axis A to the gas (e.g., air) flowingtherethrough. Each gas flow opening 1902 can be circular or non-circular(e.g., rectangular, squared and/or square-cornered) in geometry. In someembodiments, the gas flow openings 1902 have substantially uniformdimensions. In some embodiments, as shown in FIGS. 19 a and 19 b , thegas flow openings 1902 are at least partially defined by slots 1903 atthe distal end 1910 of the swirl ring 1007. These gas flow slots 1903are formed by a plurality of extensions 1904 spaced apart at regular ornon-regular intervals around the circumference of the distal end 1910,where each slot 1903 is situated between a pair of the extensions 1904.Upon the swirl ring 1007 being engaged to the nozzle 1010, the slots1903 are closed off by the proximal portion 1706 of the nozzle 1010 tocreate bounded holes. Hence, each gas flow opening 1902 can be atwo-piece composite opening cooperatively defined by the nozzle 1010 andthe swirl ring 1007. The nozzle 1010 can control the swirling strengthof a gas therethrough by dimensioning the size and shape of the gas flowopening 1902 upon assembly.

In some embodiments, the swirl ring 1007 has a set of fins 1914 radiallyspaced around an external surface between the distal end 1910 andproximal end 1912. As illustrated in FIG. 19C, three fins 1914 aredisposed around an external surface of the swirl ring 1007. Fewer ormore fins are possible. The fins 1914 are configured to radially alignand center the swirl ring 1007 relative to the retaining cap 1014 uponassembly of the cartridge 1000. As described above, when the innercomponent 1004 and the outer component 1002 are joined to form thecartridge 1000, the rear portion of the inner component 1004, which caninclude the swirl ring 1007, can be substantially suspended within thehollow body of the outer component 1002 and can be relatively detachedfrom the outer component 1002 other than at the point of engagementbetween the inner and outer components. The fins 1914 are configured toradially align the swirl ring 1007 within the hollow body of the outercomponent 1002 (i.e., within the cavity defined by the inner wall of theretaining cap 1014) by limiting a radial movement of the swirl ring 1007within the hollow body. Thus, each fin 1914 has a radial length 1916that can be less than or equal to the radial distance between theexternal surface of the swirl ring 1007 (i.e., without the fins 1914)and the inner surface of the retaining cap 1014 when the swirl ring 1007is centered within the retaining cap 1014. The fins 1914 can havesubstantially uniform dimensions. The fins 1914 can be a plurality ofprotrusions spaced apart at regular or non-regular intervals around anexternal circumference of the swirl ring 1007. The radial spacingbetween the fins 1914 allows gas to flow therethrough. In addition, eachfin 1914 can be constructed such that there is a clearance between thefin 1914 and the corresponding inner sidewall of the retaining cap 1014when the swirl ring 1007 is centered within the retaining cap 1014 toallow a gas flow therethrough. Alternatively, the fins 1914 can belocated on other components of the cartridge 1000 to accomplish the sameradial alignment function. For example, the fins 1914 can be disposed inan internal surface of the outer component 1002, such as on an internalsurface of the retaining cap 1014, to radially align the inner and outercomponents upon engagement. In some embodiments, the fins 1914 comprisea mechanism (not shown) for securing the swirl ring 1007 to theretaining cap 1014 via, for example, snap fit. This connection canreplace the securement mechanism between the nozzle 1010 and the swirlring 1007 at the interface 1021.

As described above, the crown 1006 can be a part of the inner component1004 of the cartridge 1000 in FIG. 10 . In some embodiments, the crown1006 is substantially the same as the end cap 106 illustrated in FIGS. 7a and 7 b . FIGS. 20 a and b are exemplary configurations of the crown1006 of the cartridge 1000 of FIG. 10 . The crown 1006 provides at leastone of the following functions: (i) rotatably engaging and axiallysecuring or fixedly securing the swirl ring 1006 at the proximal end1912 of the swirl ring 1006 to form the interface 1023, thereby aligningthe electrode 1008; (ii) mating with a cathode (not shown) of a torchhead (not shown) upon assembly of the cartridge 1000 into a plasma arctorch (not shown); (iii) providing a holder for the resilient element1026; and (iii) passing an electrical current from the cathode (e.g., apower contact for directing current from a power supply) to theelectrode 1008 in a blow-back contact-start configuration.

As illustrated in FIG. 20 a , the crown 1006 has a substantially hollowbody 2000 defining a proximal end 2020 and a distal end 2022. The hollowbody 2000 includes a circular raised portion 2002 and a depressed center2004. The circular raised portion 2002 defines a substantially hollowprotrusion extending toward the proximal end 2020 of the crown 1006 andthe depressed center 2004 defines a cavity extending away from theproximal end 2020. The depressed center 2004 can be defined by arelatively cylindrical sidewall 2004 a and a relatively flat bottom wall2004 b. In some embodiments, the body 2000 of the crown 1006 has asubstantially uniform thickness, thereby promoting efficient and uniformcurrent passage and assisting with the establishment of preciseconsumables alignment. Uniform thickness of the crown 1006, coupled witha stamp manufacturing technique, also simplifies manufacturing andminimizes manufacturing cycle time, consumable weight, and materialusage.

In some embodiments, similar to the crown 106, an interior surface 2008of the raised portion 2002 at the proximal end 2020 defines a biasingsurface for physically contacting and electrically communicating withthe resilient element 1026. The resilient element 1026 can bias againstthe proximal end of the electrode 1008 so as to move the electrode 1008away from the crown 1006. That is, the resilient element 1026 issituated between and physically contacts the biasing surface 2008 of thecrown 1006 and the proximal end of the electrode 1008 such that theresilient element 1026 imparts a separation force between the electrode1008 and the biasing surface 2008.

In some embodiments, similar to the crown 106, an interior surface ofthe depressed center 2004 of the crown 1006 at the distal end 2022defines a contact surface 2010 that is configured for physical contactand electrical communication with a corresponding contact surface 1044of the electrode 1008 at its proximal end. During the transferred arcmode, the contact surface 2010 of the crown 1006 is in an abuttingrelationship with the corresponding contact surface 1044 of theelectrode 1008. However, during the initiation of a pilot arc in thepilot arc mode, the contact surface 2010 is in a spaced relationshipwith the corresponding contact surface 1044 that is defined by anabsence of contact between the two surfaces.

In some embodiments, similar to the crown 106, the resilient element1026 is generally maintained between the crown 1006 and the electrode1008. The resilient element 1026 can be a part of the inner component1004 and can be secured to either the crown 1006 or the electrode 1008.In other embodiments, the resilient element 1026 is secured to both theelectrode 1008 and the crown 1006. For example, the resilient element1026 can be secured by welding, soldering, bonding, fastening, adiametral interference fit or another type of friction fit to the crown1006 and/or the electrode 1008. In some embodiments, the substantiallyhollow body 2000 of the crown 1006 is configured to house the resilientelement 1026 between its biasing surface 2008 and the proximal end ofthe electrode 1008. For example, the raised portion 2002 of the crown1006 can function as a holder of the resilient element 1026.Specifically, the resilient element 1026 can be held in place by thebiasing surface 2008, an inner interior surface 2012, and an outerinterior surface 2014 of the raised portion 2002, where the diameter ofthe inner interior surface 2012 with respect to the longitudinal Axis Ais slightly smaller than the inner diameter of the resilient element1026, and the diameter of the outer interior surface 2014 with respectto the longitudinal Axis A is slightly larger than the outer diameter ofthe resilient element 1026.

In some embodiments, radial movement of the resilient element 1026 isfurther restrained by the proximal end 1912 of the swirl ring 1007 afterthe swirl ring 1007 is affixed to the crown 1006. As shown in FIG. 10 ,after the crown 1006 is coupled to the swirl ring 1007 (e.g., by beingcrimped into the engagement groove 1932 of the swirl ring 1007), the lipportion 1934 of the swirl ring 1007 can extend into the interior of theraised portion 2002 of the crown 1006. Therefore, the lip portion 1934can further restrain and guide the positioning of the resilient element1026 inside of the crown 1006.

In some embodiments, the depressed center 2004 of the crown 1006 isconfigured to substantially surround and house a cathode (not shown) ofa torch head (not shown) when the cartridge 1000 is coupled to the torchhead. The cathode can physically mate with at least one of the side wall2004 a or bottom wall 2004 b of the cavity defined by the depressedcenter 2004. Upon mating with the cathode, the crown 1006 is adapted topass an electrical current from the cathode to the electrode 1008 in apilot mode or transferred arc mode of operation. For example, in a pilotmode of operation, an electrical current can be passed from the cathode,substantially through the side wall 2004 a of the crown 1006, to theresilient element 1026 and to the electrode 1008. In a transferred arcmode of operation, an electrical current can be passed from the cathode,substantially through the bottom wall 2004 b of the crown 1006, anddirectly to the electrode 1008 via the contact surfaces 2010, 1044.

In some embodiments, the raised portion 2002 is configured to contactand activate a consumable sensor inside of the plasma arc torch uponinstallation of the cartridge 1000 onto a torch head. This function ofthe raised portion 2002 will be described in detail below with referenceto FIG. 22 . In some embodiments, an opening (not shown) extending froman interior surface to an exterior surface of the crown 1006 is disposedon the tip of the raised portion 2002. The lip portion 1934 of the swirlring 1007 can extend proximally into the crown 1006 through the openingto contact and activate the consumable sensor inside of the torch. Insome embodiments, at least one optional vent hole 2016 (or gas exitorifice) is disposed in the crown 1006, extending from an interiorsurface to an exterior surface of the body 2000, to cool the cartridge1000 (e.g., cooling the resilient element 1026). For example, the venthole 2016 can be located at the proximal tip of the raised portion 2002.In some embodiments, the lip portion 1934 of the swirl ring 1006 canextend through the vent hole 2016 to activate the consumable sensor. Insome embodiments, the swirl ring 1007 is a part of the crown 1006.

In an alternative embodiment, as illustrated in FIG. 20 b , an opening2030 extends from an interior surface to an exterior surface of thecrown 1006 at the distal end 2022 of the crown 1006. The opening 2030thus replaces the bottom wall 2004 b of the cavity defined by thedepressed center 2004. In this case, the cathode is adapted to extendthrough the opening 2030 and physically contact the electrode 1008 inthe transferred arc mode.

In another aspect, a component can be inserted between the nozzle 1010and the outer component 1002 to control gas flow therebetween. FIG. 21shows an exemplary spacer component 2150 that can be generally locatedbetween an outer surface of the middle portion 1705 of the nozzle 1010and an inner surface of the middle portion 1107 of the retaining cap1014. The spacer 2150, which can be in the form of a washer, can be apart of the inner component 1004 (i.e., secured to the inner component1004), a part of the outer component 1002 (i.e., secured to the innercomponent 1002), or a stand-alone piece. The spacer 2150 can be a thin,substantially circular disk with a circular opening 2152 disposed in thecenter that is configured to surround a circumference of an externalsurface of the nozzle 1010 at its middle portion 1705. For example, thespacer 2150 can be dimensioned such that (i) its outer diameter 2156 isabout the same as or smaller than the interior diameter of the middleportion 1107 of the retaining cap 1014, but greater than that of thedistal portion 1106 of the retaining cap 1014; and (ii) the diameter2158 of the circular opening 2152 is same as or greater than that of themiddle portion 1705 of the nozzle 1010, but less than that of theproximal portion 1706 of the nozzle 1010. In some embodiments, thecircular opening 2152 has a plurality of gas passageways 2154 (e.g., inthe form of rectangular slots, half circles, irregular shapes, letters,etc) connected thereto. The gas passageways 2154 can be radiallydispersed around the circular opening 2152 at regular or irregularintervals. In some embodiments, the size, number and/or shape of the gaspassageways 2154 are adjustable for different processes to permitdifferent amount and/or pattern of gas therethrough. The spacer 2150 canbe made from an electrically conductive material, such as brass, copperor aluminum.

FIG. 22 shows an exemplary plasma arc torch 2100 including the cartridge1000 of FIG. 10 and a torch head 2102. Generally, the hollow region 1022of the cartridge 1000 (as shown in FIG. 10 ) is configured to receivethe torch head 2102 and couple the torch head 2102 thereto. FIG. 23 isan exemplary configuration of the torch head 2102 of FIG. 22 . The torchhead 2102 defines a distal end 2202 and a proximal end 2204 along thelongitudinal axis A. As shown, the distal end 2202 of the torch head2102 generally has an outer circular portion 2206, an inner cavityportion 2208 surrounded by the outer circular portion 2206, and acathode 2210 disposed in the cavity portion 2208, all of which areconcentrically aligned along the longitudinal axis A. A consumablesensor 2104 can also be disposed in the cavity 2208 inside of the torchhead 2102 substantially parallel to the cathode 2210. The outer circularportion 2206 can extend further distally along the longitudinal axis Athan the cathode 2210. In some embodiments, an external surface of theouter circular portion 2006 includes one or more threads 2212 configuredto engage the cartridge 1000. In some embodiments, the consumable sensor2104 is a switch located in the interior of the torch head 2102. Theconsumable sensor 2104 can be in the form of a plunger, such that whenit is not activated, the plunger is in an extended positon. Uponactivation of the consumable sensor 2104, the torch 2100 can provide aflow of current from the torch head 2102 to the cartridge 1000 to enabletorch operations.

Referring to FIG. 22 , the hollow region 1022 of the cartridge 1000 isshaped and dimensioned to complement the distal end 2202 of the torchhead 2102 such that (i) the center cavity portion 1022 a of the hollowregion 1022 is adapted to mate with the cathode 2210 of the torch head2102 and (ii) the extended tubular portion 1022 b of the hollow region1022 is adapted to mate with the outer circular portion 2206 of thetorch head 2102. The center cavity portion 1022 a (i.e., the cavitydefined by the depressed center 2004 of the crown 1006) substantiallysurrounds and physically contacts at least a portion of the cathode 2210by physically receiving the cathode 2210 extending into the cartridge1000. Thus, the crown 1006 is disposed between the cathode 2210 and theelectrode 1008, and the crown 1006 is adapted to electricallycommunicate with the cathode 2210 and/or the electrode 1008.Specifically, the depressed portion of the crown 1006 provides aninterface that allows the cathode 2210 to maintain direct electricalcommunication with the electrode 1008 at least in a transferred arc modeoperation. In some embodiments, if there is an opening 2030 at thebottom of the depressed portion of the crown 1006 (as shown in FIG. 20 b), the cathode 2210 can be disposed through the opening 2030 to maintaindirect electrical communication and physical contact with the electrode1008 at least in a transferred arc mode operation. In some embodiments,the cathode 2210 can be adjacent to and extend substantially parallel tothe resilient element 1026.

In some embodiments, mating between the cathode 2210 and the centercavity portion 1022 a of the hollow body 1022 prevents the innercomponent 1004 (or at least the crown 1006 of the inner component 1004)from rotating in the radial plane, thereby radially locking the crown1006 into position. Such mating also allows the raised portion 2002 ofthe crown 1006 to press against the consumable sensor 2104 (e.g., topush the plunger into a retracted position), thereby activating thesensor 2104 and permitting the torch to operate. In alternativeembodiments, one or more raised features (not shown) in other elementsof the cartridge 1000 (e.g., on the swirl ring 1007) can extendproximally pass the crown 1006 to press against the consumable sensor2104 and activate the sensor 2014. For example, the lip portion 1934 ofthe swirl ring 1007 can extend pass the vent hole 2016 or another hole(not shown) of the crown 1006 to contact and activate the consumablesensor 2104.

Because the inner component 1004 and the outer component 1002 of thecartridge 1000 are independently rotatable in the axial plane, radiallocking of the inner component 1004 still permits the outer component1002 to rotate axially. Hence, upon fixed engagement between the cathode2210 and the inner component 1004, an operator can rotate the outercomponent 1002 axially such that the threads 1104 disposed on an innersurface of the retaining cap 1014 fixedly engage the complementarythreads 2212 on the outer surface of the torch head 2102 to furthersecure the torch head 2102 to the cartridge 1000. Alternatively, threadscan be disposed on the inner component 1004, such as on an outer surfaceof the swirl ring 1007 to engage the torch head 2102.

In some embodiments, the sealing device 1030, such as an o-ring, iscoupled to an external surface of the swirl ring 1007 near its proximalend 1912 to engage an internal surface of the torch head 2102 when thecartridge 1000 is coupled to the torch head 2102. The sealing device1030 is configured to provide a leak-proof seal of fluids (e.g., gases)between the cartridge 1000 and the torch head 2102 at that location.

In some embodiments, the signal device 2106, such an electricallywritable and/or readable device, is attached to the swirl ring 1007 ofthe cartridge 1000 to transmit information about the swirl ring 1007and/or other cartridge components in the form of one or more signals.Exemplary information encoded on the signal device 2106 can includegeneric or fixed information, such as a consumable's name, trademark,manufacturer, serial number, and/or type. In some embodiments, theencoded information is unique to the consumable, such as metalcomposition of the consumable, weight of the consumable, date, timeand/or location of when the consumable was manufactured, etc.Information encoded to the signal device 2106 can also specify operatingparameters and/or data about the consumable that is independent of adetectable physical characteristic of the consumable. The signal device2106 can be a radio-frequency identification (RFID) tag or card, barcode label or tag, integrated circuit (IC) plate, or the like. In someembodiments, the signal device 2106 is a circular RFID tag coupledaround an external surface of the swirl ring 1007 (e.g., via snap fit)near its proximal end 1912. Generally, the signal device 2106 can be apart of the cartridge 1000 and positioned at a location in the cartridge1000 away from metallic components that can interfere with signaltransmission and reception. In some embodiments, a receiver 2107 can bedisposed in the torch head 2102 or the cartridge 1000 to receiveinformation wirelessly transmitted by the signal device 2106. Thereceiver 2107 is adapted to process these signals to extract thepertinent data and forward the data to a processor (not shown) foranalysis.

FIGS. 24 a and b show exemplary pilot arc current flow paths through thecartridge 1000 of FIG. 10 during pilot arc initiation. Specifically,FIG. 24 a shows an exemplary pilot arc current flow path 2400 throughthe cartridge 1000 if the electrode 1008 has at least one flange 2402disposed around a circumference of the electrode body. In a pilot arcmode of torch operation, the flange 2402 is adapted to make contact withthe nozzle 1010 instead of the distal end 2404 of the electrode 1008. Inaddition, there may be a clearance between the distal end 2404 of theelectrode 1008 and the nozzle 1010 when the flange 2402 makes contactwith the nozzle 1010. As describe above, a pilot arc current 2400 can beprovided by a power supply (not shown) from the torch head 2102 to thecartridge 1000 upon activation of the consumable sensor 2104. As shown,the pilot arc current 2400 is adapted to travel from the cathode 2210 ofthe the torch head 2102, via the body 2000 of the crown 1006 where itcontacts the cathode 2210, to the resilient element 1026 housed insideof the crown 1006. The pilot arc current 2400 can pass to the electrode1008 through the resilient element 1026 that biases the electrode 1008against the nozzle 1010. As the resilient element 1026 urges theelectrode 1008 into an abutting relation with the nozzle 1010 at theflange 2402, there is an absence of physical contact and electricalcommunication between the contact surface 2010 of the crown 1006 and thecorresponding contact surface 1044 of the electrode 1008. The resilientelement 1026 can be configured to pass substantially all of the pilotarc current 2400 from the crown 1006 to the electrode 1008. The current2400 continues to flow from the flange 2402 of the electrode 1008, tothe nozzle 1010 and return to the power supply via the retaining cap1014 and the torch head (not shown).

FIG. 24 b shows an exemplary pilot arc current flow path 2450 throughthe cartridge 1000 if the electrode 1008 does not have anynozzle-contacting feature (e.g., the flanges 2402) other than the distalend 2404, where the hafnium 1042 is located. In this configuration, thepilot arc current path 2450 is similar to the pilot arc current path2400 except the distal end 2404 of the electrode 1008 is adapted tocontact the nozzle 1010 as the resilient element 1026 urges theelectrode 1008 into an abutting relation with the nozzle 1010.

After pilot arc initiation, a gas is introduced into the plasma chamber1040 between the electrode 1008 and the nozzle 1010. Gas pressure canbuild within the plasma chamber 1040 until the pressure is sufficient toovercome the separation force exerted by the resilient element 1026. Atthat point, the gas pressure moves the electrode 1008 toward the crown1006 and away from the nozzle 1010 along the longitudinally axis A(while compressing the resilient element 1026) until the correspondingcontact surface 1044 of the electrode 1008 comes into physical contactwith the contact surface 2010 of the crown 1006. As the electrode 1008is moved away from the nozzle 1010 by gas pressure, an arc is generatedor initiated in the plasma chamber 1040 to form a plasma arc or jet thatcan be transferred to a workpiece (not shown).

FIG. 25 shows an exemplary transferred arc current flow path through thecartridge 1000 of FIG. 10 during transferred arc mode of torchoperation. In this mode, the corresponding contact surface 1044 of theelectrode 1008 engages in substantially planar physical contact with thecontact surface 2010 of the crown 1006 to establish electricalcommunication (e.g., electrical current passes between crown 1006 andthe electrode 1008 at the interface of the contact surface 2010 and thecorresponding surface 1044). When the contact surface 2010 of the crown1006 abuts the corresponding surface 1044 of the electrode 1008, acurrent path is established such that at least a portion of the currentpasses directly between the two components. When the arc has beentransferred to the workpiece, a cutting current is supplied to the torch(e.g., during transferred arc mode). The cutting current can be passedfrom the cathode 2210, through the crown 1006, to the electrode 1008during transferred arc operation via (1) the resilient element 1026and/or (2) the interface between the contact surfaces 2010, 1044. Insome embodiments, as illustrated in FIG. 25 , the current path 2500 thatis directly from the cathode 2210 to the electrode 1008 via the crown1006 has lower resistance and/or higher conductance than the currentpath from the cathode 2210, to the crown 1006, and through the resilientelement 1026 to the electrode 1008. The lower resistance in the currentpath 2500 is further enhanced by the fact that the crown 1006 physicallycontacts both the cathode 2210 and the electrode 1008 during thetransferred arc mode. Hence, substantially all of the electrical current2500 for sustaining a plasma arc (in transferred arc mode) can be passeddirectly between the contact surfaces 2010, 1044.

Generally, the inner component 1002 is substantially conductive tosupport both the pilot arc mode and the transferred arc mode ofoperations. In addition, the crown 1006 can maintain direct physical andelectrical contact with the cathode 2210 in both the pilot arc mode andtransferred arc mode. The crown 1006 can also maintain direct physicaland electrical contact with the electrode 1008 in the transferred arcmode. In some embodiments, there is an opening in the bottom wall 2004 bof the depressed center 2004 of the crown 2006 that allows the cathode2210 to physically contact and electrically communicate with theelectrode 1008 in the transferred arc mode. In the pilot arc mode, thecathode 2210 may be physically separated from the electrode 1008 due tothe separation force applied by the resilient element 1026 on theelectrode 1008.

FIG. 26 is an exemplary gas flow path through the cartridge 1000 of FIG.10 . A gas flow 2602 can be introduced into the cartridge 1000 andtravel toward the distal end 1017 of the outer component 1002 in achannel between an interior surface of the retaining cap 1014 and anexterior surface of the swirl ring 1007. The gas flow 2602 is adapted tomove over the fins 1914 disposed in the channel, where the fins 1914 canbe on an external surface of the swirl ring 1007 and/or on an internalsurface of the retaining cap 1014. The gas flow 2602 is bifurcated atthe distal end 1910 of the swirl ring 1007, with (i) an electrodecooling flow 2604 directed through the set of gas flow slots 1903 on thedistal end 1910 of the swirl ring 1007 and (ii) a retaining cap flow2608 generally directed between the nozzle 1010 and the retaining cap1014. As depicted, the electrode cooling flow 2604 can be furtherbifurcated into two portions, a plasma chamber flow 2606 and a vent flow2607. The plasma chamber flow 2606 travels distally between an externalsurface of the electrode 1008 and an internal surface of the nozzle 1010to cool both the electrode 1008 and the nozzle 1010 before reaching theplasma chamber 1040 to constrict the plasma arc therein. The plasmachamber flow 2606 can exit the plasma chamber 1040 through a nozzle exitorifice of the nozzle 1010 and the shield exit orifice 1506 of theshield 1012. The vent flow 2607 is adapted to travel in a reversedirection to the proximal end 1018 of the outer component 1002 and exitthe cartridge 1000 through the vent hole 2016 in the crown 1006.

The retaining cap flow 2608 is adapted to travel in a channel between aninternal surface of the retaining cap 1014 and an external surface ofthe nozzle 1010. In some embodiments, the retaining cap flow 2608 cantravel through one or more gas passageways 2154 on the spacer component2150 located between the middle portion 1107 of the retaining cap 1014and the middle portion 1705 of the nozzle 1010. These gas passageways2154 can be sized and dimensioned to regulate the gas flowstherethrough. The retaining cap flow 2608 can continue to the section ofthe channel between the distal portion 1106 of the retaining cap 1014and the middle portion 1705 of the nozzle 1010. In some embodiments, theflat elements 1710 a on the external surface of the nozzle 1010 providespacing between the nozzle 1010 and the retaining cap 1014 to permit gasflow therethrough. At the distal portion 1106 of the retaining cap 1014,one or more vent holes 1102 disposed on the retaining cap 1014 allowsthe retaining cap flow 2608 to flow out of the channel between theretaining cap 1014 and the nozzle 1010 and bifurcate into two portions—adistal shield flow 2610 and a proximal shield flow 2612. The distalshield flow 2610 can travel toward the distal end 1017 of the outercomponent 1002 between the nozzle 1010 and the shield 1012 and exit thecartridge 1000 through either the shield exit orifice 1506 of the shield1012 or the one or more vent holes 1504 on the shield 1012. The distalshield flow 2610 can cool the nozzle 1010 and the shield 1012. Theproximal shield flow 2612 can flow proximally to pass through the slots1306 and the gas channels 1318 of the insulator component 1028 disposedbetween the shield 1012 and the retaining cap 1014/cap sleeve 1016assembly. The proximal shield flow 2612 can exit the cartridge 1000 viaat least one vent hole 2620 located between the cap sleeve 1016 and theshield 1012. The proximal shield flow 2612 is adapted to cool theinsulator component 1028 and the shield 1012.

In some embodiments, swirling and/or mixing of the gas flows (i.e.,characterized by the presence of axial, radial, and circumferentialcomponents in the gas flows) can occurs at several locations throughoutthe cartridge 1000, such as at locations where the flow channels arerelatively straight. For example, swirling and/or mixing of the ventflow 2607 can occur as it travels through the crown 1006. As anotherexample, swirling and/or mixing of the retaining cap flow 2608 can occuras it travels in the channel between the interior surface of the distalportion 1106 of the retaining cap 1014 and the exterior surface of themiddle portion 1705 of the nozzle 1010. As yet another example, swirlingand/or mixing of the proximal shield flow 2612 can occur as it flowsproximally through the insulator component 1028.

FIG. 27 is an exploded view of the cartridge 1000 of FIG. 10 . FIG. 27shows the shield 1012, the insulator component 1028, the cap sleeve1016, the retaining cap 1014, the spacer component 2150, the nozzle1010, the insert 1042, the electrode 1008, the resilient element 1026,the swirl ring 1007, the crown 1006, the sealing device 1030, and thesignal device 2106. During assembly of the outer component 1002, the capsleeve 1016 can be overmolded onto the retaining cap 1014 tosubstantially surround at least the middle portion 1107 and the proximalportion 1108 of the retaining cap 1014. The distal portion 1106 of theretaining cap 1014 can be substantially exposed. The insulator component1028 can be fixed secured to the distal end 1208 of the cap sleeve 1016(e.g., via snap fit) such that the distal portion 1106 of the retainingcap 1014 also passes through the opening 1316 of the insulator component1028 and is substantially exposed. FIGS. 14 a-c show an exemplaryassembly of the retaining cap 1014, the cap sleeve 1016 and theinsulator component 1028. The shield 1012 can be fixedly secured to thecap sleeve 1016 and the insulator component 1028 (e.g., via crimping).In some embodiments, at least one of the shield 1012, the insulatorcomponent 1028, the cap sleeve 1016 and the retaining cap 1014 (such asall of these components) form the outer component 1002. Upon assembly,the elements of the outer component 1002 are radially and concentricallyaligned with respect to the longitudinal axis A.

During assembly of the inner component 1002, the electrode 1008 ishoused in the chamber formed by the coupling of the nozzle 1010 to thedistal end 1910 of the swirl ring 1007. The nozzle 1010 can be securelyaffixed to the swirl ring 1007 (e.g., via crimping). Thisinterconnection secures the electrode 1008 within the inner component1002 while the inner wall of the swirl ring axially aligns the electrode1008 about the longitudinal axis A with respect to the nozzle 1010 suchthat the electrode 1008 is limited in its axial motion. The resilientelement 1026 is inserted into the swirl ring 1007 from its proximal end1912 until it contacts the relatively flat proximal end of the electrode1008 within the swirl ring 1007. The crown 1006 is then securely affixedto the proximal end 1912 of the swirl ring 1007 while substantiallyconfining the resilient element 1026 in the raised portion 2002 of thecrown 1006 and axially aligning the resilient element 1026 relative tothe crown 1006. The crown 1006 can be connected to the swirl ring 1007through crimping, for example. This interconnection enables the biasingsurface 2008 of the crown 1006 to bias the resilient element 1026against the proximal end of the electrode 1008, thereby urging it intoan abutting position with the nozzle 1010. This interconnection alsolongitudinally aligns the electrode 1008 with respect to the crown 1006such that during the transferred arc mode, the electrode 1008 is onlyable to retract from the nozzle 1010 far enough until it abuts thecontact surface 2010 of the depressed center 2004 of the crown 1006.

In some embodiments, the sealing device 1030 is disposed around anexterior surface of the swirl ring 1007 either before or after the crown1006 is affixed to the swirl ring 1007. In some embodiments, the signaldevice 2106 is disposed around an exterior surface of the swirl ring1007 to store and transmit information about one or more components ofthe cartridge 1000.

To assemble the cartridge 1000, the optional spacer 2150 can be firstdisposed into the substantially hollow body of the outer component 1002from the proximal end 1206 of the cap sleeve 1016. The spacer 2150 candistally advance within the hollow body of the outer component 1002until it reaches the distal end of the middle portion 1107 of theretaining cap 1014 and cannot advance further to move into the distalportion 1106 of the retaining cap 1014. At this point, the spacer 2150is adapted to fit around and radially align with an interiorcircumference of the middle portion 1107 of the retaining cap 1014. Theinner component 1004 can also be disposed into the hollow body of theouter component 1002 from the proximal end 1206 of the cap sleeve 1016.The distal end 1704 of the nozzle 1010 is adapted to move through theopening 2152 of the spacer 2150 and the opening in the distal portion1106 of the retaining cap 1014. Such distal advancement of the innercomponent 1004 stops when the proximal portion 1706 of the nozzle 1010contacts the spacer 2150 and the nozzle 1010 can no longer move throughthe opening 2152 of the spacer 2150. At this point, an operator cancouple the outer component 1002 to the inner component 1004 to form theinterface 1020 by rotatably engaging and axially securing the retentionfeature 1102 of the retaining cap 1014 with the retention feature 1708on the nozzle 1010 (e.g., via snap fit) such that the two components arepermitted to rotate independently relative to each other uponengagement.

In some embodiments, the engagement between nozzle 1010 and theretaining cap 1014 at the interface 1020 is fixed both axially andradially. Instead, rotational engagement and axial securement can occurat one of the interfaces 1021 or 1023. For example, the nozzle 1010 canbe fixedly secured to the retaining cap 1014 at the interface 1020.Rotational engagement and axial securing between the inner and outercomponents occurs instead at the interface 1021 between the swirl ring1007 and the nozzle 1010. As another example, the nozzle 1010 and theswirl ring 1007 can both be fixedly secured at the interfaces 1020 and1021. Rotational engagement and axial securement between the inner andouter components occurs instead at the interface 1023 between the crown1006 and the swirl ring 1007.

In some embodiments, a method is provided to assemble the cartridge 1000of FIG. 10 . The method can include disposing the inner component 1004within a hollow body of the outer component 1002. In some embodiments,the spacer 2150 can be first disposed in the hollow body of the outercomponent 1002 prior to disposing the inner component 1004 within thehollow body. The method includes rotatably engaging and axially couplingthe inner and outer components together by axially restraining the outercomponent 1002 relative to a forward portion of the inner component 1004(e.g., at the nozzle 1010 of the inner component 1004) while permittingindependent rotation of the inner and outer components relative to eachother. After such engagement, a rear portion of the inner component 1004(e.g., the swirl ring 1007, the electrode 1008, the crown 1006 and theresilient element 1026) can be substantially suspended and radiallyoriented within the hollow body of the outer component 1002. Such radialalignment between the inner and outer components can be assisted by thefins 1914 that can be disposed on the surface of the swirl ring 1007 oranother cartridge component (e.g., an inner surface of the retaining cap1014).

The inner component 1004 can be assembled by disposing the electrode1008 inside of a hollow body of the swirl ring 1007, retaining theelectrode 1008 within the hollow body by fixedly securing the nozzle1010 to the distal end 1910 of the swirl ring 1007, and fixedly securingthe crown 1006 to the proximal end 1912 of the swirl ring 1007. Theouter component 1002 can be assembled by over-molding the cap sleeve1016 onto the retaining cap 1014. In some embodiments, the outercomponent 1002 can further include the insulator component 1028 and/orthe shield 1012 fixedly connected to the cap sleeve 1016 and/or theinsulator component 1028.

The cartridge 1000 can be coupled to the torch head 2102 of the plasmaarc torch 2100 to enable torch operations. During assembly, the torchhead 2102 can be inserted into the hollow body 1022 of the cartridge1000 such that (i) the cathode 2210 of the torch head 2102 physicallymates with the center cavity portion 1022 a of the hollow body 1022 thatis defined by the recess of the crown 1066, and/or (ii) the extendedouter circular portion 2206 of the torch head 2102 physically mates withthe tubular portion 1022 b of the hollow body 1022. In thisconfiguration, the crown 1006 is positioned between the cathode 2210 andthe electrode 1008 and the three components are radially andlongitudinally aligned. The crown 1006 is adapted to be aligned with theconsumable sensor 2104, at which position the inner component 1004 isradially fixed while the outer component 1002 of the cartridge 1000 isstill independently rotatable. Thus, an operator can rotate the outercomponent 1002 to engage the threads 1104 on internal surface of theretaining cap 1014 of the cartridge 1000 with the complementary threads2212 on the external surface of the outer circular portion 2206 of thetorch head 2102, thereby securing the torch head 2102 to the cartridge1000. Specifically, as the threads 1104 of the retaining cap 1014 arebeing rotated relative to the complementary threads 2212 of the torchhead 2102, the outer component 1002 moves both radially (rotation withthe threads 1104) and axially (advancement toward the torch head 2102),and the inner component 1004 can move axially advancing toward the torchhead 2102, but not radially. When the threads 1104, 2212 are engaged,the torch head 2102 is fully seated.

In some embodiments, after the engagement of the torch head 2102 and thecartridge 1000, the raised portion 2002 of the crown 1006 or theextended lip 1934 of the swirl ring 1007 presses against the consumablesensor 2104 located in the interior of the torch head 2102 to activate aflow of electrical current from the cathode 2210 of the torch head 2102to the cartridge 1000. The flow of electrical current enables one of apilot arc mode or a transferred arc mode of torch operation. In thepilot arc mode of operation, the electrical current flows from thecathode 2210 to the biasing surface 2008 at the proximal end 2020 of thecrown 1006, to the resilient element 1026 and to the electrode 1008 as apart of the current path. In the transferred arc mode of operation, theelectrical current flows from the cathode 2210 to the contact surface2010 at the distal end 2022 of the crown 1006, and to the correspondingcontact surface 1044 of the electrode 1008 as a part of the currentpath. Alternatively, in the transferred arc mode, the electrical currentcan flow directly from the cathode 2210 to the electrode 1008 as the twocomponents physically contact each other.

Generally, additional embodiments and modifications of the variousconsumable components for forming a cartridge of the present invention,including additional manufacturing techniques for these consumablecomponents, are possible. In some embodiments, a shield of the cartridgeof the present invention can be made from a stamping technique, such asthe shield 600 of FIG. 8 that is compatible with the cartridge 100, theshield 1012 of FIG. 15 that is compatible with the cartridge 1000, orthe shield 1600 of FIG. 16 that is also compatible with the cartridge1000. For example, after the shield is formed by stamping of a piece ofmetallic blank, such as a piece of brass, no additional machining isrequired. In some embodiments, various features of a shield, includingthe hollow body, the shield exit orifice and the gas vent holes, aregenerated at about the same time via the same stamping process. In someembodiments, one or more discrete threads, similar to the threads 1104on the retaining cap 1014 of FIGS. 12 a and 12 b, can be stamped arounda proximal portion of a shield via the same stamping process. Thesethreads enable the shield to be threaded onto a cartridge, such as ontoa cap assembly of a cartridge that includes a cap sleeve and a retainingcap, as described above. In alternative embodiments, the proximalportion of the shield produced from a stamping process is relativelysmooth without threads or other protruding features such that it can becrimped onto the cap assembly of the cartridge to irremovably affix theshield to the cartridge. In general, using a stamping procedure toproduce a shield simplifies manufacturing, as well as reduces materialcost and the cost of cycle time in comparison to traditionalmanufacturing techniques. In many cases, the cost of producing a shieldvia stamping is only about 10% of the cost of producing a similar shieldusing a traditional machining process.

FIGS. 28 a and 28 b show an exemplary assembly of multiple componentsfor forming at least a portion of the cartridge 1000 of FIG. 10 ,according to some embodiments of the present invention. As shown, theassembly includes a shield 2802, an insulator ring 2804, and a capassembly 2806 comprising a cap sleeve 2808 over-molded onto at least aportion of a retaining cap 2810. The cap sleeve 2804 can besubstantially similar in structure and composition to the cap sleeve1016 described above. The retaining cap 2810 can be substantiallysimilar in structure and composition to the retaining cap 1014 describedabove. The shield 2802 can be substantially similar in structure andcomposition to the shield 1012 or the shield 1600 described above.

Each of the retaining cap 2810 and/or the shield 2802 can be constructedfrom an electrically and/or thermally conductive material, such ascopper or brass. By using an electrically conductive material in theretaining cap 2810, a pilot current can be conducted from the nozzle tothe torch (and on to the power supply) through the electricallyconductive portion of the retaining cap 2810. Each of the cap sleeve2808 and the insulator ring 2804 can be manufactured from anelectrically insulating material, such as a plastic material (e.g.,nylon resin), a thermal-set plastic material, or a high-temperaturethermoplastic material. In some embodiments, the thermoplastic materialcomprises a polymer formed of ether and ketone molecules (e.g., etherketone based compounds), such as polyetheretherketone (PEEK). In someembodiments, the insulating material comprises Vespel® manufactured byDupont™, Torlon, Celazole or Phenolic compounds. For example, theinsulator ring 2804 can be constructed from Vespel® (manufactured byDuPont™) using an injection molding technique, a stamping technique, ora more traditional machining technique.

As shown, the cap sleeve 2808 is over-molded onto the external surfacesof the middle and proximal portions of the retaining cap 2810 to formthe cap assembly 2806. Only the distal portion 2812 of the retaining cap2810 is fully exposed in the cap assembly 2806. This over-moldingprovides electrical insulation from the pilot current running throughthe metal portion of the retaining cap 2810. In general, the capassembly 2806 defines a proximal end 2814 and a distal end 2816extending along a longitudinal axis A of the plasma arc torch. Theproximal end 2814 of the cap assembly 2806 can substantially comprisethe proximal portion of the cap sleeve 2908, and the distal end 2816 ofthe cap assembly 2806 can substantially comprise the distal portion 2812of the retaining cap 2810. As shown in FIG. 28 a , the insulator ring2804 includes a substantially hollow cylindrical body defined by aninterior surface 2818, an exterior surface 2820, a distal edge 2904 anda proximal edge 2906. The shield 2802 includes a body that issubstantially hollow. The hollow body of the shield 2802 has a proximalend 2822 and a distal end 2824 aligned along the longitudinal axis A,where the distal end 2824 comprises a shield exit orifice 2826. Theshield 2802 can be formed using the stamping process explained above.

In some embodiments, the distal end 2816 of the cap assembly 2806 isirremovably affixed to the insulator ring 2804. Specifically, theinterior surface 2818 of the insulator ring 2804 is configured tosubstantially surround the exterior surface of the distal end 2816 ofthe cap assembly 2806 and permanently engage with the exterior surfaceof the distal end 2816, such that the two components are radially andlongitudinally aligned relative to each other to form a part of aconsumable cartridge. This permanent engagement can be achieved using astaking process. FIG. 29 shows an exemplary interface 2902 formedbetween the cap assembly 2806 and the insulator ring 2804 of FIGS. 28 aand 28 b using a staking process, according to some embodiments of thepresent invention. Specifically, by pressing/staking the exteriorsurface of the distal end 2816 of the cap assembly 2806 adjacent to thedistal edge 2904 and/or the proximal edge 2906 of the insulator ring2804, at least one circumferential protrusion 2908 is formed on theexterior surface of the cap assembly 2806 that holds the insulator ring2804 in place by preventing a longitudinal movement of the insulatorring 2804 relative to the cap assembly 2806. In some embodiments, onlystaking at the distal edge 2904 of the insulator ring 2804 is needed toprevent a distal movement of the insulator ring 2804. Proximal movementof the insulator ring 2804 is prevented by the cap sleeve 2808 which isadapted to contact the proximal edge 2906 of the insulator ring 2804after the insulator ring 2804 is fitted around the distal end 2816 ofthe cap assembly 2806, as illustrated in in FIG. 28 a.

In some embodiments, the insulator ring 2804 is irremovably affixed tothe shield 2802. Specifically, the interior surface at the proximal endof the hollow body of the shield 2802 is configured to substantiallysurround the exterior surface 2820 of the insulator ring 2804 andpermanently engage with the exterior surface 2820 of the insulator ring2804, such that the two components are radially and longitudinallyaligned relative to each other to form a part of a consumable cartridge.This permanent engagement can be achieved using a crimping process. Bypermanently affixing the shield 2802 to the retaining cap 2806, bothcomponents may be disposed of as a single unit. FIG. 30 shows anexemplary interface 3002 formed between the shield 2802 and theinsulator ring 2804 of FIGS. 28 a and 28 b using a crimping process,according to some embodiments of the present invention. Such crimpinginvolves piercing (or otherwise deforming) the proximal end 2822 of thehollow body of the shield 2802 at a location where the insulator ring2804 is. The resulting piercing 3004 locks the insulator ring 2804 inplace against the shield 2802, which is in turn locked to the capassembly 2806 as described above. The piercing 3004 is adapted toconnect an exterior surface to an interior surface of the shield 2802.In some embodiments, each piercing 3004 is place adjacent to the distaledge 2904 or the proximal edge 2906 of the insulator ring 2804 to lockthe insulator ring 2804 in place, thereby preventing a longitudinalmovement of the shield 2806 relative to the insulator ring 2804. Forexample, as shown in FIG. 31 b , multiple intermittent piercings 3004can be formed via crimping on the proximal end 2822 of the shield 2802,where the piercings 3004 are spaced into multiple rows (e.g., 2 rows)that span the width of the insulator ring 2804 along the longitudinalaxis A. One row 3102 of the piercings 3004 can be located distal to thedistal edge 2904 of the insulator ring 2804 and the other row 3104 ofthe piercings 3004 can be located proximal to the proximal edge 2902 ofthe insulator ring 2804 to deform the shield 2802 around the edges 2902,2904 of the insulator ring 2804. This piercing-crimping design retainsdistinct mechanical advantages over traditional attachment methodsbecause it is much easier and less time consuming to implement thanthreading, for example. The piercing approach for crimping furtherreinforces the resulting interface and produces a bond that is strongerthan crimping without piercing. Additionally, this design enables lowcost manufacturing of the shield 2802, such as using a stamping approachdescribed above instead of a more costly manufacturing method (e.g.,turning and/or machining) of metallic rods or blanks. This is because nocomplex engagement features, such as complementary slots and tabs, needto be built into the shield 2802 and/or the insulator ring 2804.

FIGS. 31 a and 31 b illustrate an exemplary process for forming theassembly of FIGS. 28 a and 28 b to produce a portion of the cartridge1000 of FIG. 10 , according to some embodiments of the presentinvention. The method can include providing the cap assembly 2806 thatcomprises the retaining cap 2810 and the cap sleeve 2808 that isover-molded onto at least a proximal portion of the retaining cap 2810.The distal portion 2812 of the retaining cap 2810, which extends beyondthe cap sleeve 2808 (and comprise the distal end 2816 of the capassembly 2806), provides an exterior mounting surface for connectionwith the insulator ring 2804. The method can also include disposing theinsulator ring 2804 around the distal end 2816 of the cap assembly 2806and fixedly securing the insulator ring 2804 onto the exterior mountingsurface of the cap assembly 2806. Such securement is adapted tolongitudinally and radially align the insulator ring 2804 relative tothe cap assembly 2806. The fixed securement can be achieved by stakingthe insulator ring 2804 against the exterior mounting surface of thedistal end 2816 of the cap assembly 2806 to form at least onecircumferential protrusion 2908 on the exterior mounting surface thatprevents a longitudinal movement of the insulator ring 2804 relative tothe cap assembly 2806. Thereafter, the shield 2802 is fixedly secured toan exterior surface of the insulator ring 2804 by crimping at least aportion of the proximal end 2822 of the shield body 2802 to theinsulator ring 2804. The shield 2802 can be formed using a stampingprocess as explained above. The fixed securement of the insulator ring2804 to the shield 2802 can be achieved by a piercing-crimping process.For example, two rows 3102, 3104 of intermittent piercings 3004 can beformed during crimping of the proximal end 2822 of the shield 2802. Theproximal row 3104 of the piercings 3004 are formed by crimping/piercingthe shield 2802 inward proximal to the proximal edge 2906 of theinsulator ring 2804 and the distal row 3102 of the piercings 3004 areformed by crimping/piercing the shield 2802 inward distal to the distaledge 2904 of the insulator ring 2804 to substantially entrap theinsulator ring 2804 against the shield 2802. Thus, the insulating ring2804 irremovably affixes the shield 2802 to the cap assembly 2806, whilelongitudinally and radially aligning the components relative to eachother to form a portion of the consumable cartridge 1000. The insulatingring 2804 also provides electrical insulation between the shield 2802and the cap assembly 2806. In an alternative embodiment (not shown), theinsulator ring 2804 can be coupled to an outer surface of a nozzleusing, for example, the staking technique described above. A shield canthen be attached to the insulator ring 2804 in the manner describedabove, such as using the piercing-crimping approach.

As described above with respect to FIG. 11 , a retaining cap of thepresent invention, such as retaining cap 1014 can include one or morethreads 1104 disposed at its proximal portion 1108 to engage a torchhead/body of a plasma arc torch when the cartridge 1000 is installedinto the torch. Substantially the same threading feature can be presentin the retaining cap 2810 of FIGS. 28 a and 28 b . As explained above inrelation to FIG. 11 , two or more discrete threads 1104 (e.g., threethreads) can be disposed circumferentially around an interior surface ofthe proximal portion 1108 of the retaining cap 1014 to engage a set ofcomplementary threads on the torch head/body, when at least a portion ofthe torch head is disposed in the hollow body of the proximal portion1108. The discrete threads 1104 are adapted to form concave portionsrelative to an exterior surface of the retaining cap 1014. Therefore,when the cap sleeve 1016 is over-molded onto the exterior surface of theretaining cap 1014 at its proximal portion 1108, the cap sleeve 1016 isadapted to fill in the concave portions of the threads 1104, therebyproviding rigidity and stiffness to the threads 1104. Substantially thesame characteristics apply to the cap assembly 2806 of FIGS. 28 a and 28b.

In some embodiments, the retaining cap 1104 and/or the retaining cap2810 are formed via a stamping process, For example, the retaining capof the present invention can be formed by stamping of a piece ofmetallic blank, such as a piece of brass or copper, with no additionalmachining required. In some embodiments, various features of theretaining cap, including the hollow body, the retention feature forengaging a nozzle (e.g., retention feature 1102), and the one or morediscrete threads (e.g., thread 1104), are generated at about the sametime via the same stamping process. In some embodiments, one or moreflow passages (e.g., vent holes 1112) are formed in the distal portionof the retaining cap via the same stamping process.

FIG. 32 illustrates an exemplary method 3200 for manufacturing a capassembly for the cartridge 1000 of a FIG. 10 , such as the cap assembly2806 comprising the retaining cap 2810 and the cap sleeve 2806, or thecap assembly comprising the retaining cap 1014 and the cap sleeve 1016.The method includes stamping a conductive material blank to form acylindrical body of the retaining cap that is substantially hollow (step3202). The hollow body of the retaining cap includes a distal portionand a proximal portion. The stamping process is adapted to form at leastone discrete thread (e.g., threads 1104) disposed in the hollow body andextends circumferentially around the proximal portion of the retainingcap. The thread(s) are adapted to engage a complementary thread on acorresponding component of the torch, such as the torch body/head viarotation by less than 360 degrees. The method then includes over-moldingan insulator material onto an exterior surface of the conductive hollowbody of the retaining cap to form the cap sleeve (step 3204). The capsleeve is one of a plastic material (e.g., nylon resin) or ahigh-temperature thermoplastic material comprising a polymer formed ofether and ketone molecules (e.g., ether ketone based compounds), such aspolyetheretherketone (PEEK). The over-molding of this insulator materialover the proximal portion of the retaining cap is adapted to fill in theconcave threads disposed in the hollow body of the retaining cap,thereby reinforcing the stiffness of the threads.

In general, the cap assembly of the present invention is an integralpart of the cartridge 1000, which means that the cap assembly is notindividually disposable or serviceable and needs to be disposed with thecartridge as a single unit. To form the cartridge 1000 using the capassembly 2806 of FIGS. 28 a and 28 b , the insulator ring 2804 can befixedly secured to the distal end 2816 of the cap assembly 2806 (e.g.,via staking) such that the distal end 2816 also passes through theopening of the insulator ring 2804 and is substantially exposed. Theshield 2802 can then be fixedly secured to the cap assembly 2806 via theinsulator ring 2804 (e.g., via piercing-crimping). In some embodiments,at least one of the shield 2802, the insulator ring 2804, and the capassembly 2806 (such as all of these components) form the outer component1002 of the cartridge 1000. Upon assembly, the elements of the outercomponent 1002 are radially and concentrically aligned with respect tothe longitudinal axis A. The assembly of the inner component 1004 of thecartridge 1000, which includes the electrode 1008, the nozzle 1010, andthe swirl ring 1007, is explained above with respect to FIG. 27 .

To assemble the cartridge 1000 from the inner and outer components 1002,1004, the inner component 1004 can be disposed into the hollow body ofthe outer component 1002 from the proximal end 2814 of the cap assembly2806. Specifically, the distal end 1704 of the nozzle 1010 is adapted tomove through the opening in the distal portion 2812 of the retaining cap2810 of the cap assembly 2806. An operator can then couple the outercomponent 1002 to the inner component 1004 to form the interface 1020 byrotatably engaging and axially securing the retaining cap 2810 with thenozzle 1010 (e.g., via snap fit) such that the two components arepermitted to rotate independently relative to each other uponengagement. The assembly of the cartridge 1000 from the inner componentand the outer component (which comprises the assembly of the capassembly 2806, the insulator ring 2804 and the shield 2802 describedabove with respect to FIGS. 28 a and 28 b ) can be substantially thesame as the process described above with respect to FIG. 27 .

In another aspect, the present invention features an adapter for aplasma arc torch that is configured to indicate to the torch thepresence of a consumable component within the torch. For example, theadapter can be compatible with and configured for installation inside ofthe torch 100 of FIG. 1 and/or the torch 1000 of FIG. 10 to detect thepresence of a consumable in the respective torches. FIG. 33 shows anexemplary configuration of an adapter, according to some embodiments ofthe present invention. As shown, the adapter 3300 generally includes abody 3302 that defines a longitudinal axis A between a proximal end 3304and a distal end 3306 of the body 3302. The distal end 3306 representsthe end that is closest to a workpiece when the adapter 3300 isinstalled inside of a plasma arc torch to process the workpiece, and theproximal end 3304 is the end that is opposite of the distal end 3306along the longitudinal axis A. Further, the adapter 3300 has at leastone protruding portion 3308 extending from the proximal end 3304 of itsbody 3302. For the adapter 3300 of FIG. 33 , the at least one protrudingportion 3308 includes a set of two protruding portions disposed along acircumference at the proximal end 3304 of the adapter body 3302, whereeach protruding portion extends proximally substantially parallel to thelongitudinal axis A. In alternative embodiments, the at least oneprotruding portion 3308 can have other shapes, orientations, number ofprotrusions, etc. as described in detail below. In some embodiments, theadapter 3300 is made of an electrically conductive material, such ascopper.

The adapter 3300 is configured to be inserted inside of a plasma arctorch between (i) a consumable component located relative to the distalend 3306 of the adapter body 3302 and (ii) a torch body/head of theplasma arc torch located relative to the proximal end 3304 of theadapter body 3302. For example, the adapter 3300 can be sandwichedbetween the consumable component and the torch body inside of the plasmaarc torch, such that the distal end 3306 of the adapter 3300 physicallycontacts the consumable component and the proximal end 3304 of theadapter 3300 physically contacts a portion of the torch body. In someembodiments, upon installation of the adapter 3300 in a plasma arctorch, the protruding portion(s) 3308 are positioned inside of a cavityof the torch body to physically engage a switch in the cavity. Forexample, at least one of the protruding portion(s) 3308 can engage theswitch by pressing against the switch upon installation of the adapter3300 into the plasma arc torch. The engagement of the switch canindicate to the torch system the presence of the consumable component(which is at the distal end 3306 of the adapter body 3302) in the plasmaarc torch, thereby permitting a flow of electrical current to theconsumable component to enable operation of the plasma arc torch.

FIG. 23 shows an exemplary configuration of a distal end 2202 of thetorch body 2102 that is configured to engage the at least one protrudingportion 3308 of the adapter 3300 for the purpose of consumabledetection. Even though component 2102 is referred to above as the “torchhead,” this component is hereinafter referred to as the “torch body.” Inthe context of the present invention, “torch head” and “torch body” areused interchangeably. As described above with reference to FIG. 23 , thedistal end 2202 of the torch body 2102 defines the outer circularportion 2206, the inner cavity portion 2208, and the central cathode2210. The consumable sensor 2104 is disposed in the cavity 2208substantially parallel to the cathode 2210. Specifically, the consumablesensor 2104 can be disposed in the cavity 2208 radially between thecentral cathode 2210 and a wall that defines the boundary between thecavity 2208 and the outer circular portion 2206. The protruding portions3308 of the adapter 3300 are configured to extend longitudinally intothe cavity 2208, where at least one of the protruding portions 3308activates the consumable sensor 2104, such as via depression or otherphysical contact means, to indicate the presence of a consumablecomponent at the distal end 3306 of the adapter 3300 inside of theplasma arc torch. Thus, the protruding portions 3308 are dimensioned toradially fit between the cathode 2210 and the circular wall of thecavity 2208 within the torch body 2102.

FIG. 34 shows another exemplary configuration of an adapter, accordingto some embodiments of the present invention. The adapter 3400 of FIG.34 can be substantially the same as the adapter 3300 of FIG. 33 , exceptfor the configuration of the protruding portions 3408. As shown, theadapter 3400 generally defines a cylindrical body 3402 with a proximalend 3404 and a distal end 3406 extending along a longitudinal axis A.The protruding portions 3408 of the adapter 3400 comprise a set of twoprotruding portions disposed along a circumference at the proximal end3404 of the body 3402, where each protruding portion extends in alateral direction that is substantially perpendicular to thelongitudinal axis A. Similar to the adapter 3300 of FIG. 33 , theprotruding portions 3408 of the adapter 3400 are configured to bepositioned inside of a cavity of the torch body, such as the cavity 2208of the torch body 2102 of FIG. 23 , where at least one of the protrudingportions 3408 physically engages a switch inside of the cavity, such asthe consumable sensor 2104 of the cavity 2208. Since each protrudingportion 3408 extends laterally relative to the longitudinal axis A, theprotruding portion 3408 can physically activate the consumable sensor2104 by laterally contacting the sensor 2104 within the cavity 2208 orlongitudinally depressing the sensor 2104 as it is inserted into thecavity 2208.

FIG. 35 shows an exemplary arrangement of the adapter 3400 of FIG. 34inside of a plasma arc torch 3500, according to some embodiments of thepresent invention. The plasma arc torch 3500 includes a torch body 3506.The adapter 3400 is positioned generally between the torch body 3506 anda consumable component of the plasma arc torch 3500, whose presence theadapter is configured to signal to the plasma arc torch. In someembodiments, the consumable component (of which the adapter 3400 is usedto indicate the presence) is a swirl ring 3502. In some embodiments,this consumable component is an electrode 3510. In some embodiments, theconsumable component comprises a suite of multiple consumable componentsincluding the electrode 3510, the swirl ring 3502, a retaining cap 3512and/or a cap sleeve 3508. In some embodiments, the suite of consumablecomponents forms a unitary consumable cartridge, such as the cartridge100 of FIG. 1 or the cartridge 1000 of FIG. 10 . Thus, the adapter 3400can be used to indicate to the plasma arc torch 3500 the presence of theconsumable cartridge in the torch. In some embodiments, the adapter 3400is coupled to (e.g., integrally formed with) the consumable componentprior to installation, such that the adapter 3400 and the consumablecomponent are inserted inside of the torch 3500 as one piece.Alternatively, the adapter 3400 is detached from the consumablecomponent, such that each component is installed individually into ofthe torch 3500.

As shown in the torch 3500 of FIG. 35 , the proximal end 3404 of theadapter body 3402 is in electrical communication and/or physical contactwith a cathodic element (hereinafter referred to as a cathode) 3514 ofthe torch body 3506. The distal end 3406 of the adapter body 3402 is inelectrical communication and/or physical contact with the electrode3510. When inserted inside of the plasma arc torch 3500, the protrudingportions 3408 of the adapter 3400 are oriented as such that a distalsurface 3408 a of each protruding portion 3408 is in electricalcommunication and/or physical contact with the swirl ring 3502. Inaddition, a proximal surface 3408 b of one of the protruding portions3408 is in electrical communication and/or physical contact with aswitch 3516 located inside of the torch body 3506. The contact betweenthe adapter 3400 and the switch 3516 can comprise one of the protrudingportions 3408 pushing against the switch 3516 in the proximal direction.This contact indicates to the plasma arc torch 3500 that a consumablecomponent (e.g., the swirl ring 3502, the electrode 3510, and/or acartridge comprising the swirl ring 3502 and the electrode 3510) isinstalled inside of the torch 3500, which prompts the plasma arc torch3500 to initiate a flow of current from the cathode 3514 to theconsumable component via the adapter 3400. In some embodiments, aresilient element 3520 is positioned between the distal surfaces 3408 ofthe protruding portions 3408 and a proximal edge of the electrode 3510to bias the adapter 3400 toward the torch body 3506 to activate theswitch 3516.

As shown, the switch 3516 is generally located within an inner cavity3518 at the distal end of the torch body 3506. Specifically, the cathode3514 can be disposed centrally within the cavity 3518, and the switch3516 can be located radially between the central cathode 3514 and thewall defining the cavity 3518. The switch 3516 can be a sensor in theform of a plunger, such that when it is not activated, the plunger is inan extended positon.

In alternative embodiments, an adapter of the present inventioncomprises the crown 1006 described above with reference to FIGS. 20 aand 20 b , where the at least one protruding portion of the adapter cancomprise the raised portion 2002 of the crown 1006. As described abovewith reference to FIG. 22 , when the crown 1006 is inserted within aplasma arc torch, such as the plasma arc torch 2100, mating between thecathode 2210 and the center cavity portion 1022 a of the hollow body1022 of the crown 1006 allows the raised portion 2002 of the crown 1006to press against the consumable sensor 2104 (e.g., to push the plungerof the sensor 2104 into a retracted position) in the torch body/head2102, thereby activating the sensor 2104 to indicate to the torch 2100the presence of the consumable cartridge 1000 inside of the torch 2100.In some embodiments, the at least one raised portion of the crown-shapedadapter 1006 comprise one or more raised features on other consumableelements (e.g., on the swirl ring 1007) that can extend proximally passthe crown 1006 to press against the consumable sensor 2104 and activatethe sensor 2014. For example, the lip portion 1934 of the swirl ring1007 can extend pass the vent hole 2016 or another hole (not shown) ofthe crown 1006 to contact and activate the consumable sensor 2104. Thus,the protruding portion(s) of the adapter comprises the lip portion 1934of the swirl ring 1007.

In some embodiments, the adapter of the present invention is astand-alone component that is detached from the consumable component ofwhich the adapter is used to indicate the presence to the torch, suchthat the consumable component and the adapter are installed individuallyinto the torch. In some embodiments, the adapter is coupled to (e.g.,integrated with) the consumable component prior to installation into thetorch, such that the adapter and the consumable component are insertedinside of the torch as one piece. For example, if the consumablecomponent is the cartridge 1000 of FIG. 10 , the adapter can be thecrown 1006 that is integrated with the proximal end of the swirl ringbody 1006 of the cartridge 1000, and the at least one protruding portionof the adapter comprises the lip portion 1934 of the swirl ring body1006 or the raised portion 2002 of the crown 1006, which is adapted tophysically engage the consumable sensor 2104 in the torch head 2102.

FIGS. 36 a-c show profile, side, and top views, respectively, of anexemplary consumable component 3600 that integrates the adapter 3400 ofFIG. 34 with a swirl ring portion 3602, according to some embodiments ofthe present invention. As shown, the distal end 3406 of the adapter 3400is integrally formed with a swirl ring portion 3600 configured to imparta swirling motion to a plasma gas flow for a plasma arc torch.Therefore, insertion of the consumable component 3600 into a plasma arctorch, such as the torch 3500 of FIG. 35 , allows one of the protrudingportions 3408 to depress the sensor 3516, thereby permitting a currentto flow from the cathode 3514 through the component 3600, including theswirl ring portion 3602, to enable torch operation.

In other embodiments of an adapter of the present invention (not shown),the adapter can have a similar configuration as the adapter 3300 or theadapter 3400, except for the configuration of the protruding portion(s)that extend from the proximal end of the adapter body. For example, theprotruding portion(s) can be a set of one or more fins, each extendinglongitudinally along the longitudinal axis or laterally perpendicular tothe longitudinal axis to physically engage the switch in the torch body.In yet other embodiments (not shown), at least a portion of the adapteris translatable between the consumable component and the switch in thetorch body up to a predetermined distance to engage the switch in thetorch body. As an example, the adapter can comprise an inner portion andan outer portion, where the inner portion is retractable relative to theouter portion. When the adapter is installed inside of a plasma arctorch, the inner portion can translate longitudinally within the outerportion to physically engage the switch in the torch body. Translationof the inner portion of the adapter can be caused by, for example,physical contact between the adapter and a consumable component of thetorch that pushes the inner portion in a proximal direction. As anotherexample, the entire body of the adapter can be translated proximallytoward the torch body. This translation can be caused by, for example, aresilient element (e.g., a spring) attached to the distal end of adapterbody, where the resilient element is compressed by a consumablecomponent when the adapter is inserted inside of a plasma arc torch. Ingeneral, as understood by a person of ordinary skill in the art, anadapter of the present invention can have any reasonable configurationthat facilitates (i) insertion of the adapter between a consumablecomponent and a torch body inside of a plasma arc torch and (ii)engagement of the adapter with a switch at the distal end of the torchbody to permit an electrical current flow from the torch body to theconsumable component via the adapter.

FIG. 37 shows yet another exemplary configuration of an adapter 3700,according to some embodiments of the present invention. As shown, theadapter 3700 generally includes a body that defines a centrallongitudinal axis A between a proximal end 3706 and a distal end 3708.The adapter body comprises (i) an inner portion 3702 and (ii) an outerportion 3704 that is concentrically spaced relative to the inner portion3702 about the longitudinal axis A. An electrically conductive cathodicelement 3710 is located centrally within the inner portion 3702 of theadapter 3700 and extends along the longitudinal axis A. Further, atleast one protruding portion 3712 is located at the proximal end 3706 ofthe inner portion 3702, where the at least one protruding portion 3712can be disposed radially between the central cathodic element 3710 andthe outer portion 3704. In FIG. 37 , the at least one protruding portion3712 has two protruding sections that are disposed diametricallyopposite of each other about the central longitudinal axis A and extendlongitudinally parallel to axis A. The protruding portions 3712 functionas a switch actuator to engage a switch of a torch body. The protrudingportions 3712 of FIG. 37 can be substantially the same as the protrudingportions 3308 of the adapter 3300 FIG. 33 . However, as understood by aperson of ordinary skill the art, other configurations of the protrudingportion(s) 3712 are possible and are within the scope of the presentinvention.

In some embodiments, the proximal end 3706 of the adapter 3700 isconfigured to physically engage the torch body, while the distal end3708 of the adapter is configured to physically engage one or moreconsumable components. For example, a set of one or more torch mountthreads 3714 can be located on the proximal end 3706 to engage the torchbody. As shown, the set of torch mount threads 3714 is located on aninterior surface of the outer portion 3704 at the proximal end 3706 toengage a portion of the torch body having a set of complementary threads(not shown). The resulting engagement creates a cavity (not shown, butsimilar to the cavity 3518 of FIG. 35 ) within which the protrudingportions 3712 of the adapter 3700 can align with and activate (e.g.,depress) a switch of the torch body to initiate current flow. Further,upon the engagement between the torch body and the proximal end 3706 ofthe adapter, the cathode of the torch body is adapted to align withwhile physically and/or electrically contacting the cathodic element3710 of the adapter 3700 within the cavity.

In some embodiments, a set of one or more consumable mount threads 3716is located on the distal end 3708 of the adapter 3700 to engage aconsumable component, such as a swirl ring, an electrode and/or aconsumable cartridge as explained above with reference to FIG. 35 . Asshown, the set of consumable mount threads 3716 is located on anexterior surface of the outer portion 3704 at the distal end 3708 toengage a set of complementary threads (not shown) of the consumablecomponent. The resulting engagement couples the consumable component tothe distal end 3708 of the adapter 3700, such that the cathodic element3710 of the adapter 3700 aligns with while physically and/orelectrically contacting the consumable component. In operation, uponengagement of the torch body with the adapter 3700 at its proximal end3706 and engagement of the consumable component with the adapter 3700 atits distal end 3708, the protruding portion(s) 3712 of the adapter 3700activates the switch of the torch body that signals to the plasma arctorch the presence of the consumable component in the torch. Inresponse, the torch can initiate conveyance of an electrical currentfrom the cathode of torch body to the consumable component via thecathodic element 3710 of the adapter 3700.

FIG. 38 shows an exemplary process 3800 for detecting the presence of aconsumable component in a plasma arc torch using an adapter, accordingto some embodiments of the present invention. The process 3800 starts byproviding an adapter having a body that generally defines a proximal endand a distal end with at least one protruding portion extending from theproximal end of the adapter body (step 3802). The adapter can be any oneof the adapters described above with reference to FIGS. 33-37 , or anyreasonable variations thereof. The adapter is configured for insertioninto a plasma arc torch that includes a torch body defining a cavity atits distal end with a cathode and a consumable sensing pin disposed inthe cavity. For example, the plasma arc torch can have a similarconfiguration as the plasma arc torch 3500 of FIG. 35 or the plasma arctorch 2100 of FIG. 22 . Upon installation inside of the torch, the atleast one protruding portion at the proximal end of the adapter isinserted into the cavity of the torch body (step 3804). A consumablecomponent is also installed inside of the plasma arc torch, where theconsumable component is in electrical communication and/or physicalcontact with the distal end of the adapter, which is used to detect thepresence of the consumable component inside of the torch (step 3806). Insome embodiments, the consumable component is coupled to or integrallyformed with the adapter prior to installation, such that the combinationof components are installed inside of the torch as one consumable piece.In some embodiments, the two components are detached and are installedindividually into the torch. In some embodiments, the consumablecomponent is an individual torch component, such as a swirl ring or anelectrode. In some embodiments, the consumable component is a cartridge(e.g., cartridge 1000) that encapsulates multiple individual torchcomponents.

After the installation of the adapter and the consumable componentinside of the torch, the at least one protruding portion at the proximalend of the adapter physically engages the consumable sensing pin withinthe cavity of the torch body to signal the presence of the consumablecomponent inside of the torch (step 3808). The at least one protrudingportion of the adapter can have any configuration, orientation or numberthat are reasonable for engagement with the consumable sensing pin ofthe torch body. For example, the at least one protruding portion cancomprise two protruding sections 3308 as shown in FIG. 33 that extendlongitudinally in the proximal direction to physically contact theconsumable sensing pin. The protruding sections 3308 are locateddiametrically/radially opposite relative to each other around acircumference at the proximal end 3304 of the adapter 3300. As anotherexample, the at least one protruding portion can comprise two protrudingsections 3408 as shown in FIG. 34 that extend laterally perpendicular tothe longitudinal axis A of the adapter 3400 to physically contact theconsumable sensing pin. In some embodiments, the at least one protrudingsection of the adapter is translatable in the proximal direction todepress the consumable sensing pin. In general, the consumable sensingpin of the torch body and at least one protruding portion of the adapterare radially aligned upon insertion of the adapter into the torch. Theconsumable sensing pin can be located radially between a cathode of thetorch body and a circular portion of the cavity, where the cathode iscentered within the cavity.

Following the physical engagement with (e.g., depression of) theconsumable sensing pin by the adapter, a power supply of the plasma arctorch is adapted to initiate an electrical current flow conveyed fromthe cathode of the torch body to the consumable component via theadapter. Thus, at least a portion of the adapter can be constructed froman electrically conductive material. For example, in the adapter 3700 ofFIG. 37 , the cathodic element 3710 of the adapter is electricallyconductive and configured to convey a current from the cathode of thetorch body located at the proximal end 3706 of the cathodic element 3710to the consumable component located at the distal end 3708 of thecathodic element 3710. In some embodiments, substantially the entireadapter is made from an electrically conductive material.

It should be understood that various aspects and embodiments of theinvention can be combined in various ways. Based on the teachings ofthis specification, a person of ordinary skill in the art can readilydetermine how to combine these various embodiments. Modifications mayalso occur to those skilled in the art upon reading the specification.

What is claimed is:
 1. An adapter for a plasma arc torch that includes aconsumable component and a torch body, the adapter comprising; a bodydefining a longitudinal axis between a proximal end and a distal end,the body comprising an inner portion and an outer portion; a set oftorch mount threads located on the proximal end of the body on aninterior surface of the outer portion, the set of torch mount threadsconfigured to engage the torch body; a set of consumable mount threadslocated on the distal end of the body on an exterior surface of theouter portion, the set of consumable mount threads configured to engagethe consumable component; an electrically conductive cathodic elementextending along the longitudinal axis, the cathodic element located inthe inner portion of the adapter body; and a switch actuator located atthe proximal end of the body, wherein the switch actuator is configuredto be inserted into a cavity of the torch body to indicate a presence ofthe consumable component within the plasma arc torch.
 2. The adapter ofclaim 1, wherein the body of the adapter is detached from the consumablecomponent.
 3. The adapter of claim 1, wherein the body of the adapter iscoupled to the consumable component.
 4. The adapter of claim 1, whereinthe consumable component is a swirl ring.
 5. The adapter of claim 1,wherein the body of the adapter is a crown attached to a proximal end ofa swirl ring.
 6. The adapter of claim 5, wherein the switch actuator isadapted to extend from the swirl ring, through an opening in the crown,to physically engage a switch of the torch body.
 7. The adapter of claim1, wherein the switch actuator is positioned radially between thecathodic element and the outer portion.
 8. The adapter of claim 1,wherein at least a portion of the body of the adapter is translatablebetween the consumable component and a cathode of the torch body up to apredetermined distance upon engagement of the adapter with the torchbody and the consumable component.
 9. The adapter of claim 1, whereinthe switch actuator is configured to engage a switch inside of thecavity of the torch body when inserted into the cavity to indicate thepresence of the consumable component within the plasma arc torch. 10.The adapter of claim 9, wherein the switch actuator comprises at leastone protruding portion configured to engage the switch by extendinglongitudinally along the longitudinal axis or laterally perpendicular tothe longitudinal axis.
 11. The adapter of claim 9, wherein theconsumable component is a consumable cartridge.
 12. The adapter of claim11, wherein the consumable cartridge comprises a swirl ring body, andwherein the adapter body is integrated with a proximal end of the swirlring body such that the switch actuator of the adapter comprises a lipportion of the swirl ring body configured to physically engage theswitch.
 13. The adapter of claim 9, wherein the inner portion of thebody is retractable relative to the outer portion of the body, the innerportion configured to translate longitudinally within the outer portionto physically engage the switch.
 14. The adapter of claim 9, wherein thebody of the adapter is configured to (i) physically contact theconsumable component at the distal end and (ii) physically contact theswitch at the proximal end via the switch actuator.
 15. The adapter ofclaim 9, wherein the switch adapter is configured to engage the switchby pressing against the switch upon installation of the adapter into theplasma arc torch, thereby permitting a flow of electrical current to theconsumable component to enable operation of the plasma arc torch. 16.The adapter of claim 1, wherein the set of torch mount threads isdisposed on an interior surface on the outer portion of the adapterbody.
 17. The adapter of claim 1, wherein the set of consumable mountthreads is disposed on an exterior surface on the outer portion of theadapter body.
 18. The adapter of claim 1, wherein the cathodic elementis adapted to be in electric communication with a cathode of the plasmaarc torch to convey an electrical current from the cathode to theconsumable component.
 19. A method for detecting a presence of aconsumable in a plasma arc torch that includes a torch head having (i) acavity, (ii) a cathode disposed in the cavity, and (iii) a consumablesensing pin disposed in the cavity, the method comprising: providing anadapter having a body defining a proximal end and a distal end and atleast one protruding portion extending from the proximal end of thebody; inserting the protruding portion of the adapter into the cavitysuch that the protruding portion is nested radially between the cathodeand a wall of the cavity; installing the consumable inside of the plasmaarc torch; physically activating, by the protruding portion of theadapter, the consumable sensing pin in the cavity to indicate thepresence of the consumable; and permitting, based on the physicalactivation, a flow of electrical current from the cathode to theconsumable to enable operation of the plasma arc torch.
 20. The methodof claim 19, further comprising physically contacting, by the distal endof the adapter, the consumable.
 21. The method of claim 19, wherein theconsumable sensing pin is located radially between the cathode and acircular portion of the cavity, and wherein the cathode is centeredwithin the cavity.
 22. The method of claim 19, further comprising:initiating an electrical current flow by a power supply of the plasmaarc torch permitted by the physical activation of the consumable sensingpin by the adapter; and conducting the electrical current flow from thecathode to the consumable.
 23. The method of claim 19, wherein theadapter is constructed from an electrically conductive material.
 24. Themethod of claim 19, wherein the adapter is detached from the consumable.25. The method of claim 19, wherein the adapter is integrated with theconsumable.
 26. The method of claim 19, wherein physically activating bythe protruding portion of the adapter comprises one of (i) theprotruding portion extending longitudinally along a longitudinal axis tophysically activate the consumable sensing pin or (ii) the protrudingportion extending in a lateral direction perpendicular to thelongitudinal axis to physically activate the consumable sensing pin. 27.The method of claim 19, further comprising translating the protrudingportion of the adapter to depress the consumable sensing pin.
 28. Themethod of claim 19, wherein the consumable comprises a consumablecartridge that includes an electrode disposed inside of a hollow body ofa swirl ring.